Fundamentals of Industrial Instrumentation 2ed 2024

This book establishes the physical principles with mathematical analysis and practical techniques used to measure variables most important for Instrumentation applications. This text book will provide students and recent graduates with the knowledge to design and build the measurement systems for industrial processes. More number of problems as well the solutions have been provided in the second edition. AI and its specific application for Industrial Instrumentation is also covered in this book. PRELIMS.pdf Preface to the 2nd edition Acknowledgements Author biography Alok Barua CH001.pdf Chapter Introduction 1.1 Introduction 1.2 Process instrumentation systems 1.3 Instrument characteristics 1.3.1 An instrument’s span 1.3.2 The mean and standard deviation of measurements 1.3.3 Accuracy and precision 1.3.4 Linearity 1.3.5 Tolerance 1.3.6 Static error 1.3.7 Repeatability 1.3.8 Static sensitivity 1.3.9 Calibration 1.3.10 Dead zone or dead space 1.3.11 Hysteresis 1.3.12 Input impedance CH002.pdf Chapter Dynamic characteristics 2.1 Introduction 2.2 Zero-order instruments 2.3 First-order instruments 2.3.1 Step inputs 2.3.2 Ramp inputs 2.3.3 Sinusoidal inputs 2.4 Second-order systems 2.4.1 Step inputs 2.4.2 Ramp inputs 2.4.3 Sinusoidal inputs Problem 2.1 Problem 2.2 Problem 2.3 Problem 2.4 Problem 2.5 Problem 2.6 Problem 2.7 CH003.pdf Chapter Strain, load, and torque measurement 3.1 Introduction 3.2 The strain gauge 3.2.1 Implementations of strain gauges 3.2.2 The compositions of strain gauges materials 3.2.3 The bonded metal foil gauge 3.2.4 The gauge length 3.2.5 The backing material 3.2.6 The adhesive 3.2.7 Semiconductor strain gauges 3.2.8 The temperature compensation circuit 3.3 The load cell 3.3.1 Introduction 3.3.2 The use of the Wheatstone bridge in load cells 3.3.3 The column load cell 3.3.4 Some important points 3.4 The cantilever beam load cell 3.4.1 Appendix 3.5 Torque measurement 3.5.1 Introduction 3.5.2 Reaction forces in shaft bearings 3.5.3 The Prony brake 3.5.4 The measurement of torque by strain gauges 3.5.5 Installation of the strain gauges 3.5.6 The bridge output 3.5.7 Data transmission from a torque cell Problem 3.1 Problem 3.2 Problem 3.3 CH004.pdf Chapter Temperature sensors 4.1 Introduction 4.2 The thermistor 4.2.1 The manufacturing process of the thermistor 4.2.2 The thermistor in a Wheatstone bridge 4.2.3 The thermistor in a potentiometer circuit 4.2.4 The resistance of the connecting wire 4.2.5 Self-heating errors 4.3 The thermocouple 4.3.1 The law of intermediate metals 4.3.2 The law of intermediate temperature 4.3.3 Cold junction compensation 4.3.4 The junction semiconductor sensor 4.3.5 Desirable properties of a thermocouple 4.3.6 Multiple-junction thermocouple circuits or thermopiles 4.3.7 The thermocouple sheath 4.3.8 Grounded thermocouple circuits 4.4 The resistance thermometer 4.4.1 RTD circuits 4.4.2 The self-heating effect 4.4.3 The three-wire method of temperature measurement 4.4.4 The Mueller bridge or four-wire resistance method 4.4.5 Why is platinum universally used to make RTDs? 4.4.6 The construction details of the platinum RTD bulb Problem 4.1 Problem 4.2 Problem 4.3 Problem 4.4 Problem 4.5 Problem 4.6 Problem 4.7 Problem 4.8 Problem 4.9 Problem 4.10 CH005.pdf Chapter Displacement measurement 5.1 Introduction 5.2 The potentiometer 5.3 The linear variable differential transformer (LVDT) 5.3.1 The theory of the linear variable differential transformer 5.3.2 Phase-sensitive demodulation 5.3.3 Dynamic displacement measurement 5.3.4 Null voltage and its reduction 5.3.5 The LVDT design equation 5.4 Capacitive transducers 5.4.1 Variation in capacitance 5.4.2 Capacitance pickups (capacitive microphones) Problem 5.1 Problem 5.2 Problem 5.3 CH006.pdf Chapter Pressure sensors 6.1 Introduction 6.2 The Bourdon gauge 6.2.1 Absolute pressure measurement 6.2.2 The twisted Bourdon tube 6.3 The bellows gauge 6.4 The diaphragm pressure transducer 6.4.1 The semiconductor diaphragm gauge 6.5 Low-pressure measurement 6.5.1 The McLeod gauge 6.5.2 The Pirani gauge 6.5.3 The thermocouple gauge 6.5.4 The ionization gauge 6.5.5 The Knudsen gauge Problem 6.1 Problem 6.2 Problem 6.3 CH007.pdf Chapter Flowmeter 7.1 Introduction 7.2 Differential pressure flowmeters 7.3 The orifice meter 7.3.1 Orifice pressure taps 7.3.2 Restrictions on pipe fittings adjacent to an orifice meter 7.4 Flow nozzles, Dall tubes, and Venturi meters 7.4.1 The flow nozzle 7.4.2 The Venturi meter 7.4.3 The Dall tube 7.5 The Pitot tube 7.5.1 The operational principle operation of the Pitot tube 7.5.2 The differential pressure transmitter 7.6 The elbow meter 7.7 The rotameter 7.7.1 The operational principle of the rotameter 7.7.2 The shape of the rotameter float 7.8 The weir 7.8.1 The operational principle of the weir 7.9 The variable reluctance tachogenerator 7.9.1 The operational principle of the variable reluctance tachogenerator 7.10 The turbine flowmeter 7.10.1 The construction of the turbine flowmeter 7.10.2 Theory 7.11 The electromagnetic flowmeter 7.11.1 Advantages of the electromagnetic flowmeter 7.11.2 Disadvantages of the electromagnetic flowmeter 7.11.3 Field excitation 7.11.4 The use of an electromagnetic flowmeter with a metal pipe 7.12 The ultrasonic flowmeter 7.12.1 The Doppler shift ultrasonic flowmeter 7.12.2 The transit time ultrasonic flowmeter 7.12.3 Methods used to measure the time shift 7.12.4 The advantages of the ultrasonic flowmeter 7.12.5 The disadvantages of the ultrasonic flowmeter 7.13 The hot-wire anemometer 7.13.1 The hot-wire element 7.13.2 Dynamic characteristics 7.13.3 Constant current and constant temperature hot-wire anemometers 7.13.4 A comparison of constant current and constant temperature measurements Problem 7.1 Problem 7.2 Problem 7.3 Problem 7.4 Problem 7.5 Problem 7.6 Problem 7.7 Problem 7.8 Problem 7.9 Problem 7.10 Problem 7.11 Problem 7.12 Problem 7.13 Problem 7.14 CH008.pdf Chapter The flapper nozzle system 8.1 Introduction 8.2 The application of the flapper nozzle as a displacement measuring device 8.3 Static sensitivity 8.4 The force balance differential pressure transmitter 8.5 A flapper nozzle with an air relay 8.6 The current-to-pressure (I–P) transducer 8.6.1 New I–P converters 8.6.2 The piezo-ceramic bender nozzle CH009.pdf Chapter Signal conditioning circuits 9.1 Active filters 9.2 The single-amplifier filter 9.2.1 The positive feedback topology 9.2.2 The negative feedback topology 9.2.3 The enhanced negative feedback topology 9.2.4 Design equations The equal R and C design The unity gain amplifier design The Saraga design 9.2.5 The Sallen and Key low-pass filter The Saraga design 9.2.6 The Sallen and Key high-pass filter 9.2.7 The Sallen and Key band-pass filter 9.3 Negative feedback circuits 9.3.1 The band-pass circuit without positive feedback 9.3.2 The bandpass circuit with positive feedback 9.4 Inductor simulator 9.5 The low-pass filter 9.6 The high-pass filter 9.7 The band-pass filter 9.8 The state variable filter 9.9 The sample and hold circuit 9.10 The logarithmic amplifier 9.11 The antilogarithmic amplifier 9.12 The analog switch 9.13 Analog multiplexers and demultiplexers Problem 9.1 Problem 9.2 Problem 9.3 Problem 9.4 CH010.pdf Chapter Piezoelectric sensors 10.1 Introduction 10.2 The piezoelectric phenomenon 10.3 Piezoelectric materials 10.4 Piezoelectric transducers 10.4.1 The physical constants of the piezoelectric transducer 10.5 Measuring circuits 10.6 Piezoelectric accelerometers 10.7 Unimorphs 10.8 Bimorphs 10.9 Actuator stacks 10.10 Sandwich piezoelectric transducers 10.11 Pyroelectricity 10.12 Limitations of piezoelectric materials 10.12.1 Temperature limitation of piezoelectric ceramics 10.12.2 Voltage limitation 10.12.3 Mechanical stress limitation 10.12.4 Power limitation Problem 10.1 Problem 10.2 Problem 10.3 CH011.pdf Chapter Ultrasonic sensors 11.1 Introduction 11.2 Analysis 11.3 The equivalent circuit for the transmitter 11.4 The transmission of ultrasound 11.4.1 The average power intensity 11.4.2 The characteristic impedances of selected materials 11.5 Measuring ultrasound 11.5.1 Applications 11.5.2 Advantages 11.6 Special applications 11.6.1 Determining blood pressure 11.6.2 The blood flow meter Problem 11.1 Problem 11.2 CH012.pdf Chapter The measurement of magnetic fields 12.1 The measurement of magnetic fields using search coils 12.2 The Hall effect 12.2.1 Hall-effect transducers 12.2.2 The advantages of Hall-effect transducers 12.2.3 The measurement of current by Hall-effect transducers 12.2.4 Commercially available Hall-effect current transducers 12.2.5 Split ring clamp-on current transducers 12.2.6 Analog multiplication 12.2.7 Power measurement 12.2.8 Position and motion sensing Problem 12.1 Problem 12.2 Problem 12.3 Problem 12.4 CH013.pdf Chapter Optoelectronic sensors 13.1 Photoconductivity 13.2 Photocurrent 13.3 The semiconductor photodiode 13.3.1 Some typical applications 13.3.2 The measurement of steel strips in a hot rolling mill 13.4 The transmission of light in optical fibres 13.4.1 The principle of the transmission of light in two media of different refractive indices 13.5 The components of an optical fibre system 13.5.1 Fibre optic cables 13.5.2 Fibre optic transmitters 13.5.3 Fibre optic receivers 13.5.4 The transmission characteristics of fibre optic cables 13.6 Fibre optic sensors 13.6.1 Intrinsic sensors 13.6.2 Extrinsic sensors CH014.pdf Chapter The measurement of pH and viscosity 14.1 An introduction to pH 14.2 Why is pH measurement important? 14.3 The pH probe 14.3.1 The functions of the electrode 14.3.2 The glass electrode 14.3.3 The reference electrode 14.3.4 The combined pH probe 14.3.5 The practical range of pH measurement 14.3.6 The voltage output of the pH probe 14.3.7 The pH amplifier 14.4 The measurement of viscosity 14.4.1 Velocity distribution of a liquid placed between parallel plates 14.4.2 The rotating concentric cylinder method 14.4.3 The capillary flow method 14.4.4 Industrial viscosimeters Problem 14.1 Problem 14.2 CH015.pdf Chapter Dissolved oxygen sensors 15.1 Introduction 15.2 Dissolved oxygen sensing 15.3 The operational principle of the polarographic electrode 15.4 The operational principle of the galvanic electrode 15.5 Limitations of the single-layer electrode model 15.6 Electrode design 15.7 Details of some commercially available DO2 sensors 15.7.1 The Clark electrode 15.7.2 The Mancy electrode 15.7.3 The Mackereth electrode 15.7.4 The Borkowski–Johnson electrode 15.7.5 Microelectrodes 15.8 Electrode metals 15.9 Electrolytes used in DO2 probes 15.10 The membrane 15.11 Signal conditioning circuits 15.12 General design considerations 15.13 Calibrating DO2 sensors 15.13.1 Calibration based on % saturation 15.13.2 Calibration based on partial pressure 15.13.3 Calibration based on concentration CH016.pdf Chapter Gas chromatography 16.1 Introduction 16.2 Different methods of chromatography 16.3 The basics of chromatography 16.3.1 The column 16.3.2 The sample injection system 16.3.3 The temperature-controlled chamber 16.3.4 The detector 16.3.5 The operational principle 16.3.6 The chromatic behaviour of solutes 16.3.7 Quantitative analysis 16.4 Liquid chromatography 16.4.1 The solvent delivery system CH017.pdf Chapter Pollution measurement 17.1 Introduction 17.2 Sample collection 17.3 Aerosol contaminants 17.4 Gaseous contaminants 17.5 Carbon monoxide detection 17.6 NOx measurement 17.7 The sulfur dioxide analyzer 17.8 Ozone detection 17.9 The detection of hydrocarbons 17.10 The air quality index 17.11 Measurement and calculation of the air quality index 17.12 The meaning or interpretation of the air quality index reading CH018.pdf Chapter Smart sensors 18.1 Integrated, smart, and intelligent sensors 18.2 The logical function of an intelligent sensor 18.3 Integration of the signal processing unit 18.4 Self-calibrating microsensors 18.5 The self-testing of smart sensors 18.6 Multisensing 18.7 The outputs of smart sensors 18.8 Applications of smart sensors and their future trends CH019.pdf Chapter Artificial intelligence and its application to sensor selection 19.1 Introduction 19.2 Elements of an AI system 19.3 Expert systems 19.4 Languages used in AI programming 19.5 Knowledge bases 19.6 The inference engine 19.7 EXSENSEL: a case study 19.8 A sample rule 19.9 An example knowledge base 19.10 Amending programs 19.11 General information for sensor selection packages 19.11.1 A sensor description 19.12 Partial source code of EXSENSEL CH020.pdf Chapter Objective test questions I Answers to objective test questions I CH021.pdf Chapter Objective test questions II CH022.pdf Chapter Solutions to problems Chapter 2 Problem 2.1 Problem 2.2 Problem 2.3 Problem 2.4 Problem 2.5 Problem 2.6 Problem 2.7 Chapter 3 Problem 3.1 Problem 3.2 Problem 3.3 Chapter 4 Problem 4.1 Problem 4.2 Problem 4.3 Problem 4.4 Problem 4.5 Problem 4.6 Problem 4.7 Problem 4.8 Problem 4.9 Problem 4.10 Chapter 5 Problem 5.1 Problem 5.2 Problem 5.3 Chapter 6 Problem 6.1 Problem 6.2 Problem 6.3 Chapter 7 Problem 7.1 Problem 7.2 Problem 7.3 Problem 7.4 Problem 7.5 Problem 7.6 Problem 7.7 Problem 7.8 Problem 7.9 Problem 7.10 Problem 7.11 Problem 7.12 Problem 7.13 Problem 7.14 Chapter 9 Problem 9.1 Problem 9.2 Problem 9.3 Problem 9.4 Chapter 10 Problem 10.1 Problem 10.2 Problem 10.3 Chapter 11 Problem 11.1 Problem 11.2 Chapter 12 Problem 12.1 Problem 12.2 Problem 12.3 Problem 12.4 Chapter 14 Problem 14.1 Problem 14.2 APP1.pdf Chapter APP2.pdf Chapter INDEX.pdf Index