Module 2
1. Objective
1.1 To verify the flow rate indicated by the flow-meter 38-541-FM.
1.2 To become familiar with the pulse flow sensor and its use with the MEDACS
2313 programmable frequency meter.
1.3 To calibrate the pulse flow sensor against a known rate of flow.
1.4 To extend the flow range of the unit by using a bypass tube on the pulse flow
sensor.
1.5 To investigate the function and configuration of the twin switched output relays.
1.6 To explore the function, construction and setting up of the manual control valve,
the solenoid valve and the Fisher Baumann 24577S control valve.
1.7 To explore the function, construction, setting up and calibration of the current to
pressure converter.
1.8 To explore the function, construction and setting up of pressure gauges and
pressure transducer / transmitters with 4-20 mA output.
2. Theory
2.1 Control Valve
The Fisher/Baumann 24000S stainless steel control valve is a pneumatically activated needle
valve, requiring a supply of compressed air between 3 to 15 pounds per square inch (psi).
The model selected for use on this unit is Air To Open (ATO), and will fail closed under the
influence of a compression spring. The valve body is fitted with a 577 trim stem.
Figure 2.1.1 Fisher/Baumann Valve & Actuator/Positioner
2.1.1 Pneumatic & Motorised Valves
The pneumatically operated valve is much favoured in the control industry for its rapid
response and reasonable accuracy, the Baumann 27000 type of valve fitted to this training
unit has typical response times of 2 seconds fully close to fully open
2.1.2 Manual Control Valve
The manual valve selected for use with the training unit is a bonnet needle valve and will
allow a fine control of flow; it may also be used as a shut off valve. The entry and exit ports
1"
are 4 BSP and are fitted with 10 mm push-in elbows of ease of connection.
Figure 2.1.2 A typical section of a manual flow control valve
2.1.3 Solenoid Valve
The solenoid valve is only capable of open/close operation and is not a control valve, but is
much used in industry for directing and redirecting flow with instant response.
1"
The solenoid operated valve supplied has 4 BSPP entry and exit ports, and a 6mm orifice
with a 24 Vdc – 14 watt coil.
Figure 2.4.1 Typical construction of a solenoid valve
2.2 Current to Pressure Converter (I-P)
The current to pressure converter supplied with the 38-023 trainer is a ‘Marsh Bellofram’ T-
1500.
The T-1500 is an Electro-Pneumatic transducer that coverts an electrical signal to a
proportional pressure output. It provides precision electro-pneumatic control to actuators,
valves, positioners, final control elements and is ideally used for high-flow control devices.
2.2.1 T-1500 I/P Transducer Principle of Operation
The T-1500 Transducer is a force balance device in which a coil is suspended in the field of a
magnet by a flexure. Current flowing through the coil generates axial movement of the coil
and flexure. The flexure moves against the end of a nozzle and creates a back pressure in
the nozzle by restricting air flow. This back pressure acts as a pilot pressure to an integral
booster relay. Consequently, as the input signal increases (or decreases for reverse acting),
output pressure increases proportionally. In the zero based T-1500, the output of the
transducer section is routed to an integral negative bias booster relay. The bias relay allows
the complete unit to regulate output pressure down to 0 psig/BAR. The bias relay also
amplifies the output of the transducer which allows the zero based units to regulate higher
output pressures than the standard T-1500.
Zero and Span are calibrated by turning easily accessible adjusting screws on the front face
of the unit. The zero adjustment causes the nozzle to move relative to the flexure. The span
adjustment is a potentiometer that limits the flow of current through the coil. A thermistor
circuit in series with the coil provides temperature compensation.
Figure 2.2.1
2.2.2 Air Connections
1. Supply Air must be instrument quality air regulated between 5 psi above maximum
output pressure up to 120 psi g/8.3 bar g.
2. Instrument-quality air consists of:
a) A dew point less than 35°F
b) No particles larger than three microns
c) Maximum oil content of 1 ppm
d) All unused ports must be plugged.
2.3 Pressure Devices
2.3.1 The bourdon Pressure Gauge
In 1849 the Bourdon tube pressure gauge was patented in France by Eugene Bourdon. It is
still one of the most widely used instruments for measuring the pressure of gasses and
liquids of all kinds, up to pressure 6500 bar. Eugene Bourdon founded the Bourdon Sedeme
Company to manufacture his invention.
The Bourdon tube, often of bonze, is a hollow curved tube of oblong section, sealed to
atmosphere and anchored at one end. When the pressure inside the tube is increased, the
tube tends to straighten. The mechanical linkage attached to the free end is used to drive a
dial pointer by means of a rack and pinion.
Adjustments for zero and span are made by changing some of the links to increase or
decrease the mechanical advantage. The mechanism is displayed through a transparent dial
in Figure 2.3.1.
Figure 2.3.1 Bourdon Gauge Internal Mechanism
http://www.practicalmachinist.com/vb/antique-machinery-history/steam-gauge-chain-
drive-284149/
2.3.2 Pressure Measurement Terminology
Absolute Pressure – is measurement referenced to sealed and evacuated volume.
Relative Pressure – is measurement referenced to atmospheric pressure, normally referred
to as gauge pressure (bar g).
Differential Pressure – is the difference in pressure measured at two separate ports.
Pressure Transducer – The pressure transducer is a Piezoresistive pressure sensor,
contained within a sealed housing, usually filled with oil, with a flexible metallic diaphragm
making contact with the medium to be measured. As the pressure in the source medium
increases the diaphragm deflects and allows the pressure to be transferred to the
measuring cell. Transducers give an un-amplified signal into separate instrumentation nor
indicator.
Pressure Transmitter – in pressure transmitters the signal conditioning is contained within
the housing and is emitted as a standard output format, such as mV, mA or volts.
2.3.3 4-20 mA Pressure Transmitter
The pressure transmitters selected for use on the ’38-540 Training Unit’, are from the
PTX82G series by Status Instruments Ltd. And have been configured by the manufacturer to
read 0-2 bar g with an output signal of 4-20 mA. The manufacturer has used highly sensitive
equipment, traceable to national standards and has set the reference zero to be equal to 1
Atmosphere at sea level, NO FURTHER CALIBRATION IS NECESSARY. However, if the
pressure transmitter is found to be out of calibration it should be returned to the
manufacturer for re-calibration. Figure 2.3.3 shows a section of a typical pressure
Figure 2.3.3
3. Equipment required
- The Process Instrumentation Services unit 38-540-PIS
- Programmable Display 38-541-PD, 2 off
- Pulse Flow Sensor 38-541-PFS
- Frequency Transmitter 38-541-PFS
- Flow-meter 38-541-FM, 2 off
- Current Loop Resistor 38-541-CLR
- Manual Control Valve 38-541-MV
- Solenoid Valve 38-541-SV
- PC with the M-Config 2 Configuration software installed
- Special serial cable to connect ‘MEDACS’ unit to the PC
- Stop Watch
- Fisher Baumann Control Valve 38-541-CV
- Flow-meter 38-541-FM
- Pressure Gauge 38-541-PG
- Current Pressure Converter 38-541-CPC
- Pressure Transmitter 38-541-PT
4. Practical
Practical 2.1 Flowmeter and Pulse Flow Sensor
Step 1 : Configure connection according figure 1.5.1. Check that all black tube are fully engaged in
the connectors before starting (see appendix A).
Figure 1.5.1
Step 2 : Close valve A and valve B. Open the manual valve about 50%. Turn on the pump power
supply. Set the flow rate to 0.4 L/min using pump control knob. Measure the time for the bottom of
the meniscus in the sight glass to increase 2 litres. Write the result in table 1.5.1
Theoretical Flow meter Recorded Litres Calculated
Time in l/min Time in Flow rate
minutes minutes l/min
5.0 (300 sec) 0.4 2
2.50 (150 sec) 0.8 2
1.250 (75 sec) 1.6 2
0.833 (50 sec) 2.4 2
0.625 (37.5 sec) 3.2 2
0.500 (30 sec) 4.0 2
Table 1.5.1
Step 3 : Plot the graph from table 1.5.1
Step 4 : Re-configure connection according figure 1.5.10. And open valve in Pulse Flow
Sensor.
Figure 1.5.10
Step 5 : Turn the pump power supply. Control current until Flow-meter 1 reach 0.8 and
write the result in table 1.5.2.
Step 6 : Repeat step 14 for 1.6 , 2.0 and 2.4 litres/min. Turn off the pump power supply.
Flow-meter 2 Programmable Total flow calculate Flow-meter 1
(litres/min) Display (litres/min) (Flow-meter 2 plus PD) (litres/min)
0.8
1.6
2.0
2.4
Table 1.5.2
Step 7 : Connect follow figure 1.5.11. Make sure Pulse Flow Sensor valve is close.
Figure 1.5.11
Step 16 : Turn on the pump power supply. And control current for pump control increase
slowly until solenoid valve “on”. Write the result. And decrease until solenoid valve “off”.
Write the result.
Solenoid Valve Frequency Programmable Flow meter 1 Flow meter 2
Transmitter (Hz) Display (litres/min) (litres/min) (litres/min)
on
off
Table 1.5.3
Question : What the Frequency Transmitter (Hz) shown when solenoid valve get on and off.
Explain the result in table 1.5.3? Why?
Practical 2.2 Control Valves
Step 1 : Make connection according figure 2.2.1
Figure 2.2.1
Step 2 : Ensure that the air pressure regulator is unlocked (by pulling the knob away from
the panel) and set to zero, by rotating anti-clockwise until the knob stops. Connect air
compressor to Air Compressor Input in Process Instrumentation Trainer.
Figure 2.2.2
Step 3 : Set the pump control to approximately 50% (5 full turns clockwise).
Step 4 : Slowly rotate the pressure regulator control knob clockwise until the pressure gauge
adjacent to regulator read 3 psi.
Step 5 : Turn on the pump control and get the pump control fully open (100%). And write
the result in table 2.2.1
Step 6 : Increase the air pressure to 6 , 9 , 12 and 15 psi. Don’t get the air pressure more
than 2.4 bar (35 psi) . And write result in table 2.2.1. Correlate air pressure , valve opening ,
water pressure and flow.
Air pressure Valve Flow in Water delivery
in psi opening % litres/min pressure
3
6
9
12
15
Table 2.2.1
Step 7 : Plot graph from data in table 2.2.1
Practical 2.3 Current to Pressure Converter (I-P)
Step 1 : Configure the PD to read 4-20 mA. And make connection according figure 2.3.1
Figure 2.3.1
Step 2 : Set the 4-20 mA (I/P – Control Valve) to maximum and the pump control to give a
flow rate of 3.2 litres/min. Close the manual control valve to reduce the maximum flow to 3
litres/min.
Step 3 : Return the 4-20 mA valve control to minimum and increase current to control
Current/Pressure Converter around 2 mA. Read the pressure in psi and write the result in
table 2.3.1 (Pressure) , table 2.3.2 (Flow).
Step 4 : Repeat step 3 to control current, follow the current in table 2.3.1. Make Air pressure 15
bar
Pressure Flow Valve
mA
in psi Opening
4
8
12
16
20
Table 2.3.1
Flow in Pressure Valve
mA
ltrs/min from PD Opening
(%)
4
6
8
10
12
14
16
18
20
Table 2.3.2
Step 5 : Plot graph from the data in table 2.3.1(Pressure) to figure 2.3.2 and table
2.3.2(Flow) to figure(Flow)
Figure 2.3.2
Figure 2.3.3
Practical 2.4 Pressure Devices
Step 1 : Make connect according figure 2.4.1
Figure 2.4.1
Step 2: Configure PD(left) to 4-20 mA. And PD(right) to 0-2 bar g.
Step 3: Increase water pump control to maximum. And slowly increase Current/Pressure
Converter for follow current data in table 2.4.1. Compare measure from pressure
gauge(analog) and programmable display (PD : digital). And write the result in table 2.4.1
Table 2.4.1
Current (mA) Pressure gauge (bar) Pressure from PD (bar g)
4
8
12
16
20
