Pressure

Instrumentation Installation Tips for Challenging

Applications
David Dlugos

Ashcroft Inc.,
250 East Main Street
Stratford, CT 06614
Email: david.dlugos@ashcroft.com
Phone: (203)-385-0664

KEYWORDS
Pressure measurement, Pressure Instruments, Slurries, Isolation Rings, Diaphragm Seals

ABSTRACT
Pressure instruments that are not properly installed can provide inadequate information, cease to
operate or fail catastrophically causing significant damage to surrounding equipment or severe injuries to
personnel. Therefore, it is extremely important to install the instrumentation properly to meet all the
environmental requirements of the application. This paper and power point presentation are focused on
the challenges an automation engineer would encounter when installing pressure measurement
instruments for difficult applications. The content will target installations where the instruments will be
used to measure high particulate media (such as slurries) in indoor and outdoor installations as well as
operating in high vibration and pulsation environments.

Measurement of corrosive media requires the pressure instruments be mounted on instrument isolators
like isolation rings or diaphragm seals. The manner in which the instrument or instruments are mounted
to the isolator can effect performance and reliability. Minimizing the number of joints used and reducing
the volume of fill fluid used will help to reduce errors caused by ambient temperature swings. If
instruments are remote mounted on capillary lines, the location of the instrument relative to the process
can affect the accuracy. The automation engineer will need to calculate this “head affect” and correct for
it.

Installing pressure instruments correctly is crucial and may affect the functionality of the system, cost and
safety.

INTRODUCTION
The role of the automation engineer is to design accurate, safe and cost effective solutions for
monitoring or controlling processes. To assist you, this paper will focus on instrument installation
challenges and ways to address them without comprising accuracy or instrument life.

Presented at the 2018 ISA Water / Wastewater and Automatic Controls Symposium
Aug 7-9, 2018 – Bethesda, Maryland, USA – www.isawwsymposium.com
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GENERAL INSTRUMENT INSTALLATION GUIDELINES

Whenever possible, instruments should be located to minimize the effects of vibration, extreme ambient
temperatures and moisture. Dry locations away from very high thermal sources (ovens, boilers etc.) are
preferred. If the mechanical vibration level is extreme, the instruments should be remotely located and
connected to the pressure source via flexible tubing (capillary). Unfortunately, this may not always be
practical. So there are ways to address the vibration on some instruments like mechanical pressure
gauges. The pressure gauges can be liquid filled with high viscosity fluids like glycerin and silicone. This
dampens the movement and Bourdon tube (tubular elastic pressure sensing element). An alternative is a
pressure gauge with a dampened movement and pointer.

INSTRUMENT ISOLATORS VALVES

A shut-off valve should be installed between the instrument and the process in order to be able to isolate
the instrument for inspection or replacement without shutting down the process. The most common
type of isolators is block and bleed valves as shown in figure 1.

Figure 1 Pressure gauge mounted on a block and bleed valve

Presented at the 2018 ISA Water / Wastewater and Automatic Controls Symposium
Aug 7-9, 2018 – Bethesda, Maryland, USA – www.isawwsymposium.com
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The three-way manifold valves (figure 2) are used with differential pressure gauges, differential pressure
transmitters and differential pressure switches. They consist of two block valves and an equalizer valve.
The three-valve manifold prevents installation pressure spikes by equalizing high and low pressure ports,
isolates the process, and permits instrument removal without interrupting the process.

Figure 2 Differential pressure gauge mounted on a three-way manifold valve

Five-way valve manifolds (figure 3) are the most common valve manifolds used with differential pressure
Instruments. Typically, the five-way manifold consists of two block valves, one equalizer valve, and two
vent or test valves. Manifold valves prevent installation pressure spikes by equalizing the pressure to
start normal operation and permits pressure bleeding and instrument calibration without physically
removing the instruments from the process. It also isolates instruments from the process to safely
remove the instruments for maintenance or calibration.

Figure 3 Differential pressure transmitter mounted on a five- way manifold valve

Presented at the 2018 ISA Water / Wastewater and Automatic Controls Symposium
Aug 7-9, 2018 – Bethesda, Maryland, USA – www.isawwsymposium.com
 Dlugos 4

CHALLENGES OF SLURRIES
When instruments will be used to measure high particulate media such as slurries (which are very
common with wastewater applications) they need to be protected from clogging. The automation
engineer will need to select an appropriate instrument isolator. Isolation rings are typically used for
slurries. There are 3 common types of isolation rings, wafer type (figure 4), bolt thru (figure 5) and
threaded (figure 6). Single or multiple instruments can be mounted to an isolation ring. Flush flange
(figure 7) and Flush threaded (figure 8) diaphragm seals can also be used.

Figure 4 Wafer Type

Figure 5 Bolt Thru Type

Figure 6 Threaded Type

Presented at the 2018 ISA Water / Wastewater and Automatic Controls Symposium
Aug 7-9, 2018 – Bethesda, Maryland, USA – www.isawwsymposium.com
 Dlugos 5

Figure 7 Flush flange diaphragm seal

Figure 8 Flush threaded diaphragm seal

To properly select an instrument and isolation ring/diaphragm seal combination the automation engineer
will need basic understanding of the isolation seals and follow the steps below.

1. Select the proper wetted materials for the process to be measured and the fill fluid. The
temperature range of the process needs to be factored into the fill fluid decision.
2. Determine displacement required. Displacement of the isolation ring/diaphragm seal needs to be
larger than the displacement the instruments need to function correctly. This is very important
when putting multiple instruments on an isolation ring. It may be necessary to consult with the
manufactures to determine if the instruments and chosen isolation seal combination will work
correctly.
3. Evaluate the required measurement accuracy and resolution needed. There may be additional
errors added by attaching instruments to the isolation rings/diaphragm seals. It is best to check
span and zero of the instruments after they have been mounted to the rings to correct or
account for any errors. Pressure switches should always be set after attaching to the seals.
4. Temperature errors can result from an expansion or contraction of the filling fluid. These errors
can be predicted by knowing specifics of the fill (i.e. total internal volume and coefficients of
expansion), the seal/ instrument assembly (i.e. volumetric spring rate and pressure range) and
temperature influences (i.e. ambient and process temperatures). The error induced is directly
related to the change in the internal volume of the fill in the assembly. This error is not a
function of the instrument pressure range. However, the final percent error does depend on the
range. A low pressure range instrument will have a higher error than a high pressure range
instrument. To minimize the temperature effect error for low pressure ranges, it is best to select
instruments with less internal volume. In smaller internal volume instruments there is less fill
fluid to expand or contract.

Presented at the 2018 ISA Water / Wastewater and Automatic Controls Symposium
Aug 7-9, 2018 – Bethesda, Maryland, USA – www.isawwsymposium.com
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MOUNTING MULTIPLE INSTRUMENTS TO ISOLATION RINGS & DIAPHRAGM SEALS

Figure 9 shows a typical isolation ring with a digital gauge and a mechanical pressure gauge for mounting
in vertical piping. The assembly includes a quick disconnect which will make the installation easier as the
isolation ring can be installed without the instruments. The instruments can be installed afterwards. The
quick disconnect prevents the fill fluid from leaking out of either the isolation ring or the instrument
assembly.

Figure 9 Typical isolation ring & instruments for vertical piping

Figure 10 shows either two or three instruments mounted on a diaphragm seal. The instruments are
mounted with a single tee fitting or a 4 way fitting to reduce the amount of fill fluid volume and
associated temperature effects which might occur if the instruments were mount in a goal post
configuration.

Figure 10 Typical multiple instruments on a diaphragm seal

Presented at the 2018 ISA Water / Wastewater and Automatic Controls Symposium
Aug 7-9, 2018 – Bethesda, Maryland, USA – www.isawwsymposium.com
 Dlugos 7

REMOTE MOUNTING OF INSTRUMENTS

If strong vibration is present, temperature of the process is too hot or cold or you’re not able to mount
the instrument(s) due to location and size constraints it is best to remote mount the instruments on
flexible tubing (capillary). Ideally the instruments are mounted at the same height as the desired
measurement point. However, most times they are mounted at a different height and now the
instruments will need to be corrected to reflect the height difference. In a common tank level example in
figure 11, the transmitter is mounted below the tank. The capillary line is connected to a diaphragm seal
with a fill fluid of silicone. The result error caused by the height difference is calculated by the equation
in figure 12 below. The specific gravity of the fill fluid is needed to calculate the offset error. Once the
error is calculated, it can be programmed into the transmitter so the transmitter outputs the corrected
values. If the measurement instrument was a mechanical pressure gauge, the gauge pointer “zero” could
be readjusted to correct for the error or the gauge manufacturer could produce a custom dial for the
particular application. This dial can also be made in other units if desired like feet or gallons.

Figure 11 Water tank with remote mounted transmitter

Where: P = Pressure in inches of water

SG = Specific Gravity
H = Height in inches

Figure 12 Equation for calculating error due to difference in measurement position height

Presented at the 2018 ISA Water / Wastewater and Automatic Controls Symposium
Aug 7-9, 2018 – Bethesda, Maryland, USA – www.isawwsymposium.com
 Dlugos 8

SUMMARY
Most applications can have instrument mounting challenges. Selection of the proper accessories,
understanding their effects and compensating for them in the measurement process can solve most of
the challenges.

Environments like slurries and applications that include vibration, pressure spikes and pulsation can be
addressed by the proper instrument selection or combination of instruments, adding an instrument
isolator and the necessary options or accessories.

ABOUT THE AUTHORS

Dave Dlugos
Global Technical Product Leader
Ashcroft Inc.
25o East Main Street
Stratford, CT 06614
Email: david.dlugos@ashcroft.com
Phone: (203)-385-0664

Has a BSEE degree and 37 years of experience in the measurement industry performing design
engineering and product management. Earned 4 US patents. Joined Ashcroft in 2007, currently as the
Global Technical Product Leader. ISA Senior member, currently District 1, DVP Elect and a Past President
of the CT Valley Section.

Presented at the 2018 ISA Water / Wastewater and Automatic Controls Symposium
Aug 7-9, 2018 – Bethesda, Maryland, USA – www.isawwsymposium.com