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Pressure Transmitter

Pressure
transmitter
s are a common and well understood technology especially within the
petroleum, petrochemical, refrigeration and fuel gas markets and they are extremely
economical compared to other technologies.

Pressure transmitters are a common and well understood technology especially
within the petroleum, petrochemical, refrigeration and fuel gas markets and they are
extremely economical compared to other technologies. If a level is to be made in an open
vessel a pressure transmitter (PT) is placed at the bottom and the head pressure caused by
the weight of the liquid can be used to calculate the height of the liquid. Differential
pressure transmitters can be used on pressurised vessels using the same principles (9).

Level measurement using pressure transmitters cannot be deployed in primary separators
as the change in temperature will impact the measurement, the change in density of the oil
during operation will impact the measurement and any fluctuation of the
oil/gas differential pressure control valve or pressure disturbances would also
impact on the reading.

Portable dP gauges are used to monitor the dP across strainers, online densitometers,
DB&B valves, prover interchange valves, and other devices. All pressure gauges shall be
equipped with calibration stickers indicating the last test or calibration date and who
performed the calibration. The calibration sticker should be clearly visible and
constructed of a rugged material. All recordings on the sticker should be made with
indelible ink. The dial gauge cover should be clear and abrasive resistant. The
pressure gauge should be readable with permanent figures and markings and equipped with a
blowout disc for safety. The scale shall be in graduations of no greater than 2 psig with
longer graduations at each 5 psig and numbered at not greater than 10 psig intervals. The
error at any point on the scale should not exceed ±2 psig. The maximum
allowable working pressure (MAWP) of the dP gauge should be at least equal to the MAWP
for the measurement facility.

A <a href="http://www.onlysft.com/pressure-transmitter/differential-pressure-
transmitter/" target="_self">differential pressure transmitter is a device that
translates physical force to an electrical signal. The most common type of force transducer
uses a diaphragm, piston, bourdon tube, or bellows to sense the physical force and various
strain/force-sensing devices to convert the deflection of the physical element to an
electrical signal. Traditional strain-sensing devices include the following: capacitive
cells, piezoresistive strain gauges, piezoelectric quartz material, and electromagnetic
devices.

In the United States, companies such as Rosemount, Cameron/Barton, Foxboro, and
Ultrasystems have provided transmitters that specialize in safety system pressure
measurements. These transmitters may still function successfully on some iPWR designs, but
many will have to be reengineered for different mounting configurations, size constraints,
and environments. Many iPWR designers, when faced with a modification program, may choose
to go with new technologies rather than modifying the old ones. The new technologies may
offer advantages in size, redundancy, accuracy, and environmental resilience. Some of these
new technologies include microelectromechanical system (MEMS) sensors, fiber optic sensors,
and ultrasonic sensors.

In the optical fiber category, a company called Luna Innovations has developed and
successfully tested fiber optic pressure sensors, like the one shown in Fig. 6.1, in a
research reactor environment. These fiber optic pressure sensors have been shown to operate
in radiation environments with flux levels much higher than those compatible with most
electronic pressure sensors. With traditional technology, it is necessary to protect
traditional electronic <a href="http://www.onlysft.com/pressure-transmitter/gauge-
pressure-transmitter/" target="_self">gauge pressure transmitter from harsh radiation
conditions near the core; this requires the use of long pressure sensing lines, which limit
the response time to pressure transients and increase the number of wall penetrations. Luna
’s fiber optic pressure sensors are designed to operate in harsh environments. When these
pressure sensors were combined with Etalon-based fiber optic temperature sensors providing
temperature compensation, drift effects were minimized. The attractiveness of this
technology for iPWRs is obvious, with the elimination of sensing lines, the minimization of
penetrations, the small size of the sensor, the rapid response to pressure fluctuations,
and the operability in high radiation fields. With these attributes, this technology bears
merit for primary and secondary side pressure measurement (Dickerson et al., 2009).

Pressure or DPT transmitters have been used to measure liquid levels of open
or pressurized tanks, respectively, with proper calibration taking care of the density
value of the subject liquid. These types are used for level measurements of boiler drums,
all heaters, deaerators, condenser hotwells, condenser surge tanks, and all
dosing tanks.

For open tanks, a pressure tapping at a suitable location is connected through the
impulse line, to the high-pressure port of the DPT with the low-pressure port open to
atmosphere. The pressure (or DP) sensed by the DPT is proportional to the level with a
known liquid density (ρ) and force due to (earth’s) gravity (g). With proper calibration,
the potential transform can now be used as a level transmitter.

Regarding the pressurized tank or vessel, single-pressure tapping does not
serve this purpose as it senses the pressure of the vessel and the pressure of the liquid
level. To balance out the vessel pressure, another pressure tapping for sensing it is
connected, through the impulse line, to the low-pressure port of a DPT so that the output
will only be proportional to the liquid level only with known ρ and g.

Another new technology for pressure sensing is the polymer-derived ceramic MEMS sensor.
At the forefront of this technology, a company, Sporian Microsystems, has developed a
pressure/temperature sensor made to survive high temperatures (Fig. 6.2). This technology
offers a solution for pressure sensing in iPWRs due to its hardy environment survivability
and its small size. The small size allows for the installation of redundant units and the
measurement of pressure at many points, possibly with fewer penetrations than traditional
sensors.

These new technologies have attributes like small size, heat
survivability, radiation hardness, fast response, and low maintenance. These attributes are
highly valued in iPWR designs for obvious reasons.

The Series-211 differential <a
href="http://www.onlysft.com/pressure-transmitter/absolute-pressure-transmitter/"
target="_self">absolute pressure transmitter can accurately measure positive,
negative or differential pressure and send the corresponding 4–20 mA output signal to
a recording system. It is not position sensitive and can be mounted in any orientation
without compromising accuracy. It also features a power LED, so one always knows when the
transmitter is operating. The compact, light-weight design makes installation simple and
easy. Two inlets for the pressure connections are located on the front of the unit, labeled
“High” and “Low”. For differential pressure measurement, the higher pressure should be
connected to the “High” pressure port. For positive pressure, the “Low” pressure port
should be left vented to atmospheric pressure. Periodically, it is necessary to recalibrate
the gauge to maintain the accuracy. For “zero” gauge, the pressure connection needs to be
removed from both pressure ports and to adjust the zero potentiometer until the output is
4 mA. To span the gauge, the full scale pressure to be applied to “High” pressure
port and to adjust the span potentiometer until the output is 20 mA. The salient
features of the pressure transmitter are compact design, LED power indication, 2-wire
design, 4–20 mA output, ± 0.25% accuracy level, 0–90 mmHg pressure range, –
25 °C to 70 °C operating temperature ranges, 2-wire output signal and 12–30
VDC power supply.

Drum level is measured by differential <a
href="http://www.onlysft.com/temperature-transmitter/thermal-resistance-temperature-
transmitter/" target="_self">thermowell temperature transmitter installed in line with
Figures XII/3.5-1(a,b). Note that for drum-level measurement a temperature-equalizing
column has been used to ensure that in both limbs of DPTs temperatures are equal, meaning
that the densities are equal. So far, the discussion has been about installation and making
the two limbs’ temperatures equal. Now level is measured by because there is an incumbent
pressure P1 at the top, which needs to be subtracted to get the level. So,
finally, one is left with P1 at the top and P1 + pressure due to water
head (P) on the other limb. Therefore DP = pressure due to water head, P = h
× ρ × g.

For a particular place, g is always constant. So water
head P varies with h (level) and density, which in turn depends on
temperature. In the drum, incumbent pressure is due to saturated steam pressure, and for
saturated steam for each pressure there is a particular temperature.
Therefore, saturation pressure is chosen to compensate/correct the density
effect. Temperature is a sluggish parameter, so pressure is chosen to compensate.

Degradation of the transmitter’s accuracy and response time (two
uncorrelated phenomena) are the two most important consequences of ageing. Ageing caused by
heat and humidity can cause the transmitter sealing materials to fail, allowing moisture to
enter the transmitter housing. This can cause calibration shifts and high-frequency noise
at the transmitter’s output, which can render the transmitter inoperable or unreliable.
Though NPP I&C failure data indicates that calibration drift accounts for anywhere from
59% to 77% of all age-related failure in pressure transmitters (fow blockage, fatigue, and
other factors accounting for the remaining age-related failures), a survey of the nuclear
industry in the early 1990s showed that fewer than 10% of NPP pressure transmitters
actually drift out of tolerance and that in a typical two-year fuel cycle only about 1–3%
of transmitters suffer calibration failure.

The analog signal operates over a 4–20 mA range (0 to 5 Vdc
with a 250 Ω high-precision pull-up resistor). For proper analog signal discrimination,
the tertiary device should be equipped with at least a 12-bit ADC converter. Digital
signals are preferred over analog signals for accuracy. However, the tertiary device must
be able to communicate with the secondary devices using a common communications protocol.
The status signals typically are used for indicating block valve status (fully
open, fully closed, in travel), generating commands to obtain a sample (activation of
sample extractor), and alarm status.

The transmitters should be equipped with a display of the current
readings at the transmitter housing in appropriate engineering units. The transmitters
should be equipped with both analog and digital output to the tertiary device.

For analog communications to the tertiary device, a 4–20 mA
signal is preferred and requires a high-precision 250 Ω pull-up resistor (to convert from
0 to 5 Vdc). The dampening parameters should be turned off or set to its lower limit. For
digital communications to the tertiary device, the update interval of the transmitter
should be less than or equal to 1 second. The transmitters should be equipped with an
appropriate communications protocol and the dampening parameters should be turned off or
set to its lower limit.

The sensing lines that bring the pressure signals from the process to
the transmitter can become partially or totally blocked due to sludge, boron solidification
(PWRs), and other debris in the reactor coolant, causing sluggish dynamic performance in
the transmitter. According to NRC data, blockages, voids, and leaks account for nearly 70%
of the age-related problems in sensing lines. Nevertheless, the effects of ageing on
response time are even less significant than the effects on calibration. The response times
of 84% of transmitters tested in a 1994 study written by the author for Nuclear safety were
unaffected by ageing. Of the remainder, only 4% delivered response times that could be
considered failing.

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