ISA IND PRESS LVL DENS MEASRMNT-2009 Industrial Pressure Level and Density Measurement (Second Edition).pdf

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1、Industrial Pressure, Level,and Density MeasurementSecond EditionGillum.book Page i Friday, November 14, 2008 1:09 PMGillum.book Page ii Friday, November 14, 2008 1:09 PMIndustrial Pressure, Level,and Density MeasurementSecond EditionDonald R. GillumGillum.book Page iii Friday, November 14, 2008 1:09

2、 PMIndustrial Pressure, Level, and Density Measurement, Second EditionCopyright 2009 by ISAInstrumentation, Systems, and Automation Society67 Alexander DriveP.O. Box 12277Research Triangle Park, NC 27709All Rights Reserved.Printed in the United States of America.10 9 8 7 6 5 4 3 2ISBN: 978-1-934394-

3、34-2No part of this work may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording or otherwise, without the prior written permission of the publisher. NoticeThe information presented in this publication is for the ge

4、neral education of the reader. Because neither the author nor the publisher have any control over the use of the information by the reader, both the author and the publisher disclaim any and all liability of any kind arising out of such use. The reader is expected to exercise sound professional judg

5、ment in using any of the information presented in a particular application. Additionally, neither the author nor the publisher have investigated or considered the affect of any patents on the ability of the reader to use any of the information in a particular application. The reader is responsible f

6、or reviewing any possible patents that may affect any particular use of the information presented. Any references to commercial products in the work are cited as examples only. Neither the author nor the publisher endorses any referenced commercial product. Any trademarks or trade names referenced b

7、elong to the respective owner of the mark or name. Neither the author nor the publisher makes any representation regarding the availability of any referenced commercial product at any time. The manufacturers instructions on use of any commercial product must be followed at all times, even if in conf

8、lict with the information in this publication.Library of Congress Cataloging-in-Publication DataGillum, Donald R.Industrial pressure, level, and density measurement / Donald R.Gillum. - 2nd ed.p. cm.ISBN 978-1-934394-34-21. Pressure transducers. 2. Level indicators. 3.Liquids-Density-Measurement. I.

9、 Title. TJ223.T7G48 2009681.2-dc222008044970Gillum.book Page iv Friday, November 14, 2008 1:09 PMAny success that I have or may ever achieve I owe to my family and close colleagues. First of all, I owe much to my Mother and Father who always had confidence in me and encouraged me to better myself wh

10、en I was happy to settle for much less. My wife, Barbara has always supported me in all endeavors. My children, Darcy and Jeff were understanding and patient when I was trying to build a career and depriving them of time we could have spent together. Darcy and Jeff have given much support, lending t

11、heir efforts in many ways including research and desktop publishing. My grandchildren, Lisa, Katie, Sarah, Samuel, Daniel and great-grandchildren Joseph and Hannah have also been patient. The little ones have been very understanding when they ask “Pa, is your book finished so you can play with us?”

12、The Instrumentation Faculty and Staff at Texas State Technical College -TSTC have been very helpful in technical support and research. Thanks to Susan Colwell and the ISA staff for their patient help in this project. Much appreciation goes to the reviewers, especially Jerry Gerlich who offered many

13、valuable recommendations.Donald R. GillumGillum.book Page v Friday, November 14, 2008 1:09 PMGillum.book Page vi Friday, November 14, 2008 1:09 PMviiTABLE OF CONTENTSList of Illustrations xvList of Tables xxvPreface xxviiAbout the Author xxix1 Introduction to Measurements 12 Pressure Measurement and

14、 Calibration Principles.72.1 Introduction 72.2 Fluid Properties Relating to Pressure Measurement 7Fluids and Pressure 7Pressure Units 10Gage and Absolute Pressure 10Manometric Principles 16Calibration Principles 282.3 Standard Instruments for Calibration 37Calibration Checks 393 Pressure Transducers

15、 and Pressure Gages 833.1 Introduction 833.2 Pressure Transducers 833.3 Pressure Elements 84Bourdon Pressure Elements 84Bourdon C-Tubes 85Spiral Pressure Elements 87Helical Pressure Elements 87Bellows 87Gillum.book Page vii Friday, November 14, 2008 1:09 PMviii Table of ContentsPressure Gages 90Accu

16、racy Standards 115Differential-Pressure Instrument Installation 1294 Transmitters and Transmission Systems 1334.1 Introduction 1334.2 Secondary Transducers 1344.3 Potentiometers 1354.4 Signal-Conditioning Circuits for Resistance Devices 1364.5 Variable Inductance Transducers 1414.6 Linear Variable D

17、ifferential Transformer 1424.7 Variable-Capacitance Transmitters 145Sensor Module 148Demodulator Circuit 148Oscillator Circuit 148Voltage Regulator 148Current Control 1494.8 Electrical Strain Gage Transmitters 1504.9 Resonant Frequency Transmitter 1534.10 Silicon Resonant Sensor 1584.11 Variable-Rel

18、uctance Transducers 1604.12 Piezoresistive Transmitters 1644.13 Flapper-Nozzle Transmitters 1654.14 Pneumatic Relay 1684.15 Negative Feedback 1704.16 Summary of Transmitter Types 1724.17 Safety Transmitters 1744.18 Differential Pressure Measurement 1764.19 Differential-Pressure Applications 1794.20

19、Closed Tank Level Measurement by Differential Pressure 1794.21 Flow Measurement by Differential Pressure 1804.22 Industry-Standard Transmitters 1844.23 The Dynamics of Pressure Transmitters 1864.24 Digital Transmitters and Field Communication 1874.25 Digital Transmitters 1884.26 Improved Digital Sen

20、sors 1884.27 Highway Addressable Remote Transducer (HART) 1904.28 Digital Transmitter Operation 1934.29 HHC Transmitter Smart Family Interface 2004.30 Topology 202Gillum.book Page viii Friday, November 14, 2008 1:09 PMTable of Contents ix4.31 Point-to-Point 2024.32 Multidrop 2034.33 Calibrating HART

21、 Field Devices 2044.34 A HART Calibrator 2054.35 Troubleshooting HART 208Field Device Malfunction 209Configuration Changed 209Cold Start 209Analog Output Current Fixed 209Analog Output Saturated 210Nonprimary Variable Out of Limits 210Primary Variables Out of Limits 2104.36 HART Summary 212FOUNDATIO

22、N Fieldbus 212Summary for FOUNDATION Fieldbus 2214.37 Applications 2224.38 Introduction to Wireless Communication 2274.39 Specifications and Standards for Wireless Technology 2284.40 Topologies 231Star 232Mesh 232Cluster-Tree 2324.41 Self-Organizing Networks 2345 Level Measurement Theory and Visual

23、Measurement Techniques2455.1 Introduction 2455.2 Visual Measurement Methods 2475.3 Dipsticks, Lead Lines, Steel Tapes with Bobweights 2475.4 Sight Glasses 2495.5 Automatic Tank Gages 254Key ATG Components 257Transmitters for Automatic Tank Gages 259Misapplication 263Application Guidelines 263Install

24、ation 264Maintenance and Preventive Maintenance 265Conclusion 2655.6 Magnetic-Type Float Devices 2665.7 Magnetic Tank Gage 268Gillum.book Page ix Friday, November 14, 2008 1:09 PMx Table of Contents5.8 Displacement Principles for Level Measurement 2705.9 Variable-Displacement Measuring Devices 2705.

25、10 Displacers Used for Interface Measurement 2765.11 Field-Mounted Interface Controllers 2785.12 Application of Displacer Actuated Level Controllers 2825.13 Maintenance and Calibration 2905.14 Multi-displacer Applications 2925.15 Instrument Mounting and Special Applications 2936 Hydrostatic Head Lev

26、el Measurement.2976.1 Introduction 2976.2 Principle of Operation 2976.3 Open-Tank Head Level Measurement 2986.4 Hydrostatic Head Level Measurement 3046.5 Diaphragm Box 3046.6 Air-Trap Method 3086.7 Air Purge or Bubble System 3086.8 Head Level Measurement in Closed-Tank Applications and Pressurized V

27、essels 3106.9 Mounting Considerations: Zero Elevation and Suppression 3126.10 A Multivariable Level Controller 3196.11 Diaphragm Seals 3226.12 Summary of Diaphragm Seal Systems 3246.13 Repeaters Used in Closed-Tank Level Measurement 3256.14 Summary of Hydrostatic Head Level Measurement 3267 Electric

28、al Level Measurement 3297.1 Introduction 3297.2 Resistance Level Measurement 3297.3 Capacitance Level Measurement 3357.4 Capacitance Measurement Techniques 3447.5 Application Considerations 3507.6 Installation Considerations 3517.7 Process Considerations 3537.8 Material to Be Measured 3537.9 Tank Co

29、nstruction Material 3547.10 Tank Pressure and Operating Temperature 3557.11 Humidity Changes 3557.12 Material Agitation 3557.13 Radio Frequency Admittance Level Measurement 355Gillum.book Page x Friday, November 14, 2008 1:09 PMTable of Contents xi7.14 Conductance Level Measurement 3617.15 Sonic and

30、 Ultrasonic Level Measurement 3617.16 Principle of Operation 3627.17 Parasitic Echoes 3687.18 Transducer-Related Parasitic Echoes 3697.19 Secondary Echoes in Covered Tanks 3707.20 Point Measurement 3727.21 Noninvasive Ultrasonic Sensors 3737.22 SummaryUltrasonic Measurement 3767.23 Radar Level Detec

31、tion 3767.24 Microwave Principle 3787.25 Pulse Radar 3787.26 Frequency Modulated Continuous Wave Radar 3807.27 Signal Evaluation for FMCW Radar 3807.28 Microwave Antenna 3837.29 Contact and Non-Contact Operation 3847.30 Tank Atmosphere 3857.31 Temperature Sensors and Display Equipment 3867.32 Applic

32、ations 3877.33 Floating-Roof Tank Installations (Pipe Installations) 3877.34 Fixed-Roof Tank Installations 3877.35 Liquefied Gas Installations 3877.36 Tank Farm Storage and Waste Chemicals 3877.37 Food Industry 3887.38 Heavy Hydrocarbon Storage Vessels 3897.39 Possible Interference Issues in Radar L

33、evel Measurement 389Multiple Reflections 389Multipath Propagation 389Other Microwave Transmitters 3907.40 End-of-the-Probe Algorithm 3907.41 Interface Detection by Time Domain Reflectometry (TDR) 3937.42 SummaryRadar Level Measurement 3947.43 Fiber-Optic Liquid Level Measurement 3967.44 Applications

34、 3977.45 Level Sensors for Refinery Vessels 3977.46 System Configurations 3987.47 Other Applications 3997.48 Factors Affecting Index Measurements 4017.49 Other Types of Level Measurement 401Gillum.book Page xi Friday, November 14, 2008 1:09 PMxii Table of Contents7.50 Magnetostrictive Level Measurem

35、ent 4027.51 Nuclear Radiation Devices 4057.52 Theory of Operation 4057.53 Applications of Nuclear Radiation Level Measurement 4077.54 Rotating Paddle 4117.55 Vibration-Type Level Measurement 4127.56 Thermal Level Measurement 4137.57 Laser Level Measurement 4157.58 Level Measurement by Weight 4187.59

36、 Mounting and Installation of Load Cells 4187.60 Hydraulic Load Cells 4207.61 Strain Gages 4208 Liquid Density Measurement .4258.1 Introduction 4258.2 Units and Definitions Related to Density 4258.3 Density Measurement by Hydrostatic Head 4298.4 Displacer Density Measurement 4348.5 Radiation Density

37、 Measurement 4368.6 Radiation Source 4388.7 Shielding 4398.8 Radiation Detectors 4398.9 Signal Conditioning 4398.10 Density Gage Applications 4408.11 Oscillating Coriolis Density Measurement 4458.12 Summary of Coriolis Measurement 4468.13 Ball-Type Density Meter 4478.14 Capacitance-Type Density Meas

38、urement 4478.15 Hydrometer 4488.16 Vibrating Spool Density Measurement 4518.17 Weight of Fixed Volume 4528.18 U-Tube Density Gage 4538.19 Insertion Liquid Density Measurement 4558.20 Microwave Density Meter 4568.21 Density Applications of Microwave Measurement 4589 Hydrostatic Tank Gaging .4619.1 In

39、troduction 4619.2 HTG Principles 4619.3 Tank Calibration 462Gillum.book Page xii Friday, November 14, 2008 1:09 PMTable of Contents xiii9.4 Tank Calibration Methods 4639.5 Tank Recalibration and Recomputation 4709.6 Recalibration Guidelines 4719.7 Recomputation Guidelines 4739.8 HTG Measurements 475

40、9.9 Applications of HTG Technology 4789.10 Vertical Cylindrical Tanks 4789.11 Liquid Petroleum Gas (LPG) Tanks 4789.12 Batch Processing 4799.13 HTG Calculations 4819.14 Calculating HTG Accuracy 4849.15 HTG Assumptions and Level Calculation 4859.16 HTG Assumptions and Gross Volume Calculation 4869.17

41、 HTG Assumptions and Mass Calculation 4869.18 HTG Assumptions and Net Volume Calculation 4879.19 Effect of Tank Geometry 4879.20 Advantages and Limitations of HTG 4889.21 New Developments and Trends 4919.22 A Multi-function Tank Gage 493MTG Construction and Design 494MTG Theory of Operation 49410 In

42、strument Selection and Applications50310.1 Introduction 50310.2 Summary of Pressure Applications 50310.3 Summary of Level Applications 508Instrument Selection 508Accuracy Statements and Reference Performance 517Accuracy Statements 518Case Histories for Various Level Applications 524Applications in S

43、olids Level Measurement 530Radar Signal Processing for Solids Application 53510.4 Summary of Solids Level Measurement 53610.5 Radar Applications in Stilling Wells and Bypass Pipes 53810.6 Head Level Measurement with Density Compensation 53910.7 Summary of Density Compensation for Head Measurement 54

44、310.8 ConclusionLevel Measurement 543Gillum.book Page xiii Friday, November 14, 2008 1:09 PMxiv Table of ContentsAppendixesA Definition of Terms 549B Deadweight Gage Calibration573B.1 Introduction 573B.2 Calibration of Piston Gages by Crossfloat 574B.3 Inspection of Weights 576B.4 Calibration of Wei

45、ghts 576B.5 Deadweight Gage Inspection and Preparation for Calibration 577B.6 Preliminary Calibration Operations 578B.7 Calibration of Piston Gages 580B.8 Crossfloat Balancing With the Proximity Indicator 581B.9 Test Report 587B.10 Adjustments of Piston Pressure Gage Weights for a Specific Environme

46、nt 588B.11 Recalibration Interval for Hydraulic Deadweight Gages 591C Pressure Instruments Form ISA-20.40a1 .593Answers to Exercises 595Index 613Gillum.book Page xiv Friday, November 14, 2008 1:09 PMxvLIST OF ILLUSTRATIONSFigure 21 Hydraulic Press 9Figure 22 Pressure Due to Gravity 11Figure 23 Press

47、ure Due to Applied Work 11Figure 24 Relationship between Absolute and Gage Pressure 16Figure 25 Relationship between Pressure and a Column of Liquid. 17Figure 26 Basic Hydrostatic Head Pressure Measurement Concept 19Figure 27 U-Tube Manometers 19Figure 28 Well Manometer 21Figure 29 Meniscus Effects

48、in Water and Mercury Manometers 21Figure 210 Inclined Manometer 25Figure 211 Examples of Repeatability and Accuracy 33Figure 212 Dead Band and Hysteresis 33Figure 213 Linearity Example 35Figure 214 Hierarchy of Calibration Standards 39Figure 215 Block Diagram of a Calibration Arrangement 40Figure 21

49、6 Deviation Plot for Example 2-17 43Figure 217 Zero Error 49Figure 218 Span Error 49Figure 219 Nonlinear Error 51Figure 220 Four-Bar Lever System 54Figure 221 Angularity in a Four-Bar System 55Figure 222 Deadweight Tester 58Gillum.book Page xv Friday, November 14, 2008 1:09 PMxvi List of IllustrationsFigure 223 Cylinder Arrangements of Piston Gages 62Figure 224 Pneumatic Deadweight Tester 71Figure 225 A Pressure Comparator Test Instrument 73Figure 226 Electronic Manometer 76Figure 227 A Multifunction Documenting Process Calibrator 79Figure 31 Block Diag