INSTRUMENTATION FOR OPERATORS Unit 1 Measuring Instruments Pressure InstrumentsInstrumentation for Operators has been designed to give you, the operator, n feeling of how instrumentation plays its role in the efficient operation of a refinery. The program is developed in three units. Unit One will familiarize you with many of the more common measuring instruments—how they work, when they are used and how they are protected from damage. Unit Two will show you how the instruments are used in the control of a process, Finally, Unit Three integrates the ma- terial taught in Units One and Two and familiarizes you with controllers and modes of control. UNIT ONE In Section 1 you will learn about pressure as an operating variable and how instruments are used to measure pressure. Instruments covered include the barometer, manometer, bour- don tube, diaphragm and bellows gage. Tn Section 2 you will learn about temperature as an operating variable and temperature-measuring instruments. You will learn the principles of the expandable-element thermometer, bimetallic thermometer and electrical thermometer.INSTRUCTIONS This is a programed learning course. Programed learning gives information in a series of steps called frames. Each frame gives some information and asks you to make use of it. Here is how it works. First, cover the response column at the right with a mask. Read this frame and use the information it gives to fill in the blank, A micrometer is an instrument designed to measure in thousandths of an inch. A micrometer is a good tool for measuring very differences in size. Move the mask down to uncover the word at the right of the frame. If you have filled the blank with that word or a word that means the same, you are ready to go ahead to the next frame. The drawing of a micrometer provides information that will help you fill in the next blanks. OBJECT TO BE MEASURED Seven major parts are shown in the drawing, but only the __________and the ______ contact the object to be measured. smal] anvil; spindle‘The next frame calls for a choice. Circle or underline the ap- propriate word. Of the two parts that contact the object, only the (anvil/ spindle) moves. A program is a series of frames that work like the ones you have just done; Read the frame. Use the information to fill in the blanks or make a choice, Move the mask down and check the response column. Go on to the next frame. Remember to cover the response column with a mask before you begin each page, spindleAN INTRODUCTION TO INSTRUMENTATION FOR OPERATORS 1. Petroleum products like gasoline and lubricants are made from erude oil, ‘To be turned into fuels, lubricants, petrochemicals and other products, the crude oil is = 2. Crude oil is processed in various pieces of equipment; the equipment used depends on the products being made, —~ NAPHTHA PRODUCT —~ KEROSINE PRODUCT —=GAS OIL PRODUCT —~ REDUCED CRUDE PRODUCT For example, this fractionating unit takes crude oil and changes it into__.______. 3. Crude oil is a mixture of many hydrocarbons, ranging from asphalt, which boils at a high temperature, to gasoline, which boils at a __________ temperature. 4, Many hydrocarbon products, for example kerosine, have boiling ranges between those of asphalt and gaso- line, Kerosine has a ([) higher/( lower) boiling range than gasoline. —- GASOLINE PRODUCT refined, or processed products. Tow higher10. iL 12. 13. 14. |. Mixture A boils at a different temperature than mix- ture B. 80% gasoline 80% kerosine 20% kerosine 20% gasoline A B Mixture (1) A/[] B) boils at the lower temperature. . To separate gasoline out of a gasoline-kerosine mix- ture by: boiling, the mixture must be heated to the right temperature. If the temperature is too (1) high/[] low) the gasoline will not boil and vaporize. . If the temperature is too __________ the kerosine will boil and vaporize with the gasoline. . If the process is to be continuous, more gasoline-kero- sine mixture must enter the process as — is separated out. . To make sure that there is enough ____________to continue the process, the flow rate of feed into the unit must be carefully controlled. If the mixture is being vaporized in a closed unit, the can't escape as the mixture is boiled. Pressure then (() inereases/C] deereases) in the closed unit. When pressure increases, the boiling temperature in- creases. ‘To boil gasoline at this increased pressure, the tempera- ture must (CJ inerease/[] decrease). Which of the following affect the separation of petro- Jeum products: temperature (D yes/O no) pressure (Q yes/Q no) feed rate (D yes/no) Pressure, temperature, and feed rate are three key variables in any fractionating process. A condition which is changeable is called a 4 low high gasoline mixture, or feed vapor increases: increase yes yes yes variable15. Liquid level also affects a process. LEVEL TOO LOW FLOODING The liquid level in these two situations (C] affects/ 1D does not affect) the operation, affects 16, Liquid level (Fj is/(] is not) a variable in refinery is processes. 17. Refined products are stored in tanks to await sale. Running over a tank is hazardous, wastes gasoline, and wastes. money 18, The liquid __________in a tank or other process level, or height vessel must be controlled.19. 20, 21. 22. 23, Process variables are related to each other. Heating water in a boiler causes its temperature to rise. The pressure inside the boiler also_______-_. ‘Temperature and___ changes in a system are directly relted to cach other. When gas or liquid is heated in a closed space, its pres- sure eta If temperature increases in a closed space, pressure A pressure difference is needed to move liquids. 24. Liquid flows from ([] A to B/[] B to A). Pressure is related to flow rate. The larger the pressure difference, the ([ higher/ Cl lower) the flow rate. increases pressure increases increases AtoB higher26. 26. 27. 28, 29. Liquid exerts pressure on the bottom of its container. 15 PSIG Pressure near the bottom of an open container depends on the height of the.________in the container. A measurement of pressure at the bottom of the con- tainer can be used to determine liquid 2 Liquid level can be determined by measuring the —_— —.at the bottom of the tank, The amount of pressure exerted by a liquid and gas in a closed tank depends on which of these three variables? temperature (C0 yes/Z] no) liquid level (Cl yes/(J no) flow of liquid into the closed tank (1 yes/[] no) When gas or liquid flows in a pipe, its pressure de- creases as it flows. A pressure change can be used to indicate the of gas or liquid flowing. 7 liquid, or level level, or height pressure yes yes yes amount, or direction30. 31. 32. 34. 35. 36. 37, ‘The higher the level of liquid in a tank, the greater the pressure at the bottom of the tank, A change in pressure at the bottom of the tank may also be used to indicate a change in liquid Liquid level and flow rate measurements can be in- dicated by measuring ___________ changes in a system, One process variable ((j is/(] is not) related to the other process variables. . Refinery equipment is complex and expensive. Without help, a man can’t keep track of all the tem- peratures, pressures, levels, and flow rates, and at the same time keep these variables from —— too much, Instruments such as flow meters, pressure gages, and thermometers are more _—___________ than man’s senses alone. Some instruments show the operator the state of the process at the moment he looks at it. 1200° FRY He can look at the dial and at the clock and see that at 1 p.m. the temperature of the provess is __° F But, at 2 p.m, the same instrument can’t tell him what the temperature was at 1 p.m, ‘The instrument measures and indicates; it ([] records/ Gi does not record), A pen and graph paper can be added to the same in- strument. Now, the instrument measures and 8 level pressure changing accurate, or dependak 1200 does not record38. Let’s say that pressure is so crucial that a unit can 39. 40. go off specifications if pressure increases even a small amount. ‘The pressure in this unit needs to be (7 automatically/ CD operator) controlled. After all, you can’t watch the pressure gage every second of every hour. ‘Vital processes are normally controlled ({] automatic- ally/[) manually). The diagram below represents a fractionating unit. Each box indicates a pressure, temperature, or flow rate which must be maintained at the exact value shown in the box. It is 2 a.m, rainy, and cold. You have a headache and your replacement is 20 minutes late. 35 PSIG 200 B/H [e20rF ] 615° F This is a job for: (pick one) C a. instruments alone ( b. operator alone ( . both instruments and operator 9 automatically automaticallySECTION ONE PRESSURE INSTRUMENTS What Is Pressure? 1, All substances are made up of molecules, ‘The molecules in a gas or a liquid move rapidly in ((] one divection/() all directions). 4 .2. "This tank is filled with molecules of butane gas. ‘These molecules strike each other and the of the tank, 3. When molecules hit something, they exert a force. The faster the molecules move, the more ——.__ they exert. 10 all directions walls force10. | AS more molecules strike an object, they exert a (Cl greater/[] smaller) amount of force. . The heavier the molecules, the ([] greater/(] smaller) the amount of force they exert. - The amount of force which molecules exert depends on: the ___..____ of the molecules, the ___________of molecules striking the object, and the ___________ of the molecules, . Pressure is force on a specific area. This block acts on an area of ________ square inch. . Pressure can be described as the amount of exerted on one square inch, . Measuring the force of molecules striking a ere inch is one way of measuring ‘The amount of pressure which molecules exert depends on: the ___________of the molecules hitting a square inch, ' the ________of molecules hitting a square inch, and the ___________of the molecules hitting a square inch. SBT greater greater speed number weight, or size one foree pressure speed number weight, or size11. Pressure is usually measured in pounds on one square inch. Pounds per square inch (abbreviated psi) is the of the molecules exerted on one square inch, 12, This block is lying on a table. << i 1 Wi he ‘The molecules are exerting force on an of one square inch of the table. 13. Now stack another block on top of the original block. The pressure at the bottom ([] increases/(] decreases), 14. The taller the block, the ([] greater/C] smaller) the amount of pressure it exerts. 15. Thus, a taller block exerts (() more/C] less) pressure than a shorter block of the same material. 16. If the block is made out of lighter material, it exerts ————____ force on one square inch than the heavier block. 12 force area increases greater more Jess17, Which of these containers exerts more pressure? Container (() A/C B). A 18. Which of these containers exerts more pressure? Container (F] A/D) B). B 19. The pressure a substance exerts depends on: the _________ of the substance, and weight the _________of the substance. height s Since the molecules of gases and liquids move in all directions, they exert force in all directions, Pressure is exerted in ([] one direction/[] all direc- tions). all directions 1321. The atmosphere is a “blanket” of gases which sur- rounds the earth. This height of atmosphere exerts 14.7 pounds of pressure on each square inch of earth. uc ATMOSPHERE Atmospheric pressure is ______ pounds per square 14.7 inch (psi) at sea level. 22, If the atmosphere were deeper, atmospheric pressure would be ([] more than/[] less than) 14.7 psi. more than 23. Look at the drawing. ATMOSPHERIC PRESSURE At the top of the mountain, the height of the atmos- phere is ((] more/{ less) than its height at sea level. less 24, Thus, the pressure that the air exerts depends on the —_— of the air. height, or depth 25. At the top of the mountain, atmospheric pressure is (CQ more/(q less) than 14.7 psi. less 426. 27, Pressure can also move liquids from one place to an- 28. 29, 80, 31. Pressure can be used to move things, So 2 PRESSURE Pressure can make this block, other. : The piston pushing down on the liquid exerts on the liquid. Since liquids cannot be squeezed, this pressure mukes some of the tank liquid _________into the tube connected to the tank. The higher the pressure, the ([] higher/[] lower) the level of liquid in the tube. If the piston is pulled back up, the liquid ((¢) stays in the tube/E] runs back into the tank), It is_________ that supports the liquid in the tube. 15 move pressure, or force move higher runs back into the tan pressure82, Atmospheric pressure can also support liquid in a tube. ATMOSPHERIC PRESSURE NO PRESSURE If there is no pressure at the top of the tube (vacuum), the pressure of the ________ pushes liquid up into the tube, 33. If the tube were open at the top, atmospheric pressure would push down there too. The liquid ((] would/f] would not) move up in the tube. 34. The liquid moves only if there is a difference in 85. The liquid moves from a (C1) high/Z low)-pressure area to a (CD high/[) low)-pressure area. 16 atmosphere would not pressure high lowHOW PRESSURE IS MEASURED The Barometer 36. This long glass tube is filled with mercury (a heavy liquid metal) ; the tube is turned over into the dish. Some of the mercury runs out of the tube and into the dish. When this happens, there is an empty space (vacuum) at the —___ of the tube. top 87. There ([j is/f is no) pressure in this space. is no 88. Since there is no pressure in this space, no downward pressure is exerted on the mereury in the (J tube/ 0 dish). tube 39. Look at this barometer. : UM ‘The pressure of the — the mercury in the dish. is pushing down on atmosphere 1740, 41. 42. 43. 44. 46. 47. Since the mereury can’t be squeezed, ——____ pressure forces some of the mercury to rise up into the tube. Repeated testing has shown that 14.7 psi of pressure supports a column of mercury 80 inches high. If the atmospherie pressure decreases, the column of mercury is ({j] more/[] less) than 30 inches, This is the barometric pressure that a weatherman talks about. When he says that the barometer is rising he means that atmospheric pressure is (7) increasing/D decreas- ing). Mercury is an extremely heavy liquid metal. 14.7 PSI Lt MERCURY WATER It takes (7 a lot of relatively little) pressure to hold the mercury up in the tube. 14.7 psi can support more ([] water/[] mereury). . To measure atmospheric pressure, you need more (@ water/(] mercury). By using mercury instead of water, a barometer tube can be made much ((¢] shorter/[] taller). A barometer indicates pressure as the of a column of mercury. 18 atmospheric less increasing a lot of water water shorter heightThe Manometer 48, Let’s take a barometer, cut off the end, and bend it 49. 50. 51. 52. into a U-shaped tube (manometer). Unlike the -barometer, both ends are exposed to pressure, Pressure on both sides of the tube is (1) the same/ C different). The liquid ([] moves/f] will not move). The liquid level is ([] the same/C] different) on each side. One end of this manometer is hooked into a gas line. 20 Ps => “ys ‘The amount of pressure pushing down at A is ([7] more/ ( less) than the amount of pressure pushing down at B. 19 atmospheric the same will not move the same‘58. 54. 55. 56. 57. 58. 59. ‘The higher pressure forces some of the liquid to rise in side When the liquid level increases or decreases, it indi- cates that pressure is changing. ‘The manometer measures the_____ between two pressures, When the level is higher in side B, you know that pres- sure is greater in ((] side A/D side B). ‘When the level is the same on both sides, there is no pressure z This manometer is measuring the difference between the pressure in a process line and the pressure of the atmosphere. The pressure at B is about ________ psi. Pressure is greater at (I) A/D) B). Suppose the pressure in the process line decreases to 18 psi. The level in B ((] increases/(j decreases). 20 difference, or change side A difference 14.7 decreases60. This manometer is measuring the pressure difference between two tanks, Pressure is greater in ((j tank A/D tank B), tank B 61, You don’t know the pressure in either tank. Can the manometer tell what the pressure is in either tank? (Cj yes/no) no 62. It can only tell you___________in pressure. differences 68. As pressure on one side of the manometer increases, the mercury rises on the other side. 40 PSI 14,7 PSI 20 Pst | . As the amount of pressure difference increases, the difference in level between the two sides _._. increases 21