Process Control Elements

Process Engineering II (EI - 309)

Lalu Seban Assistant Professor, Dept. of Electronics & Instrumentation Engineering, National Institute of Technology Silchar Lecture 9 (Module - II)

UNIT II (Lectures - 4) PROCESS CONTROL ELEMENTS: Signal conversion - I/P, P/I Converters, Pneumatic and Electric actuators, Valve Positioner, Control Valve, Characteristics of Control Valves, Types of control valves, Control valve sizing, cavitation and flashing.

Once again to the basic

In simple words

Measure the PV Evaluate (SP-PV) Decision (by controller) Action (by FCE)

In microscopic view

Language problem

Synchronization between sensor and controller, controller and FCE etc. FCE should understand what Controller speaks We need a translator (I/P, I/V, P/I) Better avoid mediators in real life

Process Control Elements

By Application Sensors A/D, D/A Converters I/P, P/I, V/I, I/V Converters Actuators/FCE

Process Control Elements

Depending on the energy source Hydraulic (pressurized uncompressiblle fluid) Pneumatic (compressed air) Electric (current, voltage)

Electric Vs Pneumatic Vs Hydraulic

Advantages
ELECTRIC
Accurate position Suit to advance control No tubing

PNEUMATIC
Inexpensive Fast No pollution No return line No stall damage

HYDRAULIC
Large capacity Locking capability Self lubricating Easy to control Smooth operation

Disadvantages
Low speed Expensive Unsafe Need breaker Overheating Low accuracy Noise pollution Difficult speed control Need infrastructure Expensive Leakage problems Difficult speed control Need return line Need infrastructure

I to P convertor

Controller speaks in I (4-20 mA) FCE understands only P (3-15 Psi) So we take the help of a mediator called I/P converter

Air supply 20 psi Current 4 to 20 mA

I/P

Pneumatic 3 to 15 psi supplied to FCE

I to P convertor

P to I convertor

Transmission over large distances Input to an electronic logger or computer Input P (3-15 Psi) Output I (4-20 mA) Make use of pressure capsule

P to I convertor

Problems.

The electrical (4-20mA) temperature transmitter is calibrated for a temperature range of 500 to 750 Kelvin. Range and Span ? Find the output of transmitter when temperature is

400K, 500K, 600K, 700K, 750K, 1000K

Is it clear

0 to 150 Psig, the range is 0 to 150 Psig, 0 for the 0%(4mA) and 150 for the 100 % (20mA), the span is 150Psig 20 to 200 Psig, the range is 20 to 200 Psig, 20 for the 0%(4mA) and 200 for the 100%(20mA), the span is 180Psig 40 to 350 F, the range is 40 to 350 F, 40 for the 0%(4mA) and 350 for the 100 % (20mA), the span is 310F

Problems.

If the input to an I/P converter is 10mA, what will be its output? 0mA, 4mA, 10mA, 12mA, 20mA Represent every signal in percentage and then proceed

Is it clear.

Signal (x) to (%)

x - xmin (%) = X 100 xmax - x min

(%) to Signal (x)

(%) x = xmin +(xmax - x min ) X 100

Process Control Elements

Process Engineering II (EI - 309)
Lalu Seban Assistant Professor, Dept. of Electronics & Instrumentation Engineering, National Institute of Technology Silchar Lecture 10 (Module - II)

Final Control Element

equipment to convert the control signal (generated by controller) into the action needed to correctly control the process The final control element adjust the amount of energy/mass goes into or out from process as commanded by the controller

Hydraulic Actuators

Using pressurised liquid for doing work Pressure in whole liquid remain equal Applications requiring large forces and precise control vehicle power steering and brakes, hydraulic jacks and heavy earth moving machines

Final Control Elements

Hydraulic Pneumatic Electric

Hydraulic Actuators
F1 P1 x A1 F 2 P 2 x A2 P1 P 2 F 2 A2 32 2 9 F1 A1 1

Electronic FCEs

Heater Blower Motors Solenoid valves

Electronic FCEs

Heater Blower Motors stepper, AC, DC Solenoid valves

Solenoid

When the coil is energized the core will be pulled in

core

coil

SOLENOID

coil

core

Solenoid

Solenoid

Control Valves

mechanism to regulate flow by opening or closing based on signal from controller

Control Valves
Linear or Rotary motion valves Electric or Pneumatic valves Air to open or Air to close valves Manual or Automatic valves Linear or Quick opening or Equal percentage valves

Linear Motion valves

closure member moves in a straight line to regulate flow Gate valve Globe valve Diaphragm valve

Rotary Motion valves

closure member moves in an angular or circular path to regulate flow Plug valve Ball valve Butterfly valve Quarter Turn Valves: rotary valves which moves from fully closed to fully open in a a quarter turn

Remember

Rotary valve : turn Clock-wise to Close

Quarter turn valve : perpendicular to pipe (line) to Close

Based on actuation

Manually turning using motors Using pneumatic pressure

air to open air to close

Valve Components

Valve Body
is the first boundary of a pressure Valve framework that holds all the parts together ends are designed to connect the Valve to the piping

Valve Disk
part which regulate flow, depending on its position. With the Valve closed, full system pressure is applied across disc valves named disc design linear motion gate, globe rotatory motion butterfly, ball

Valve Seat(s)
ensures the seating surface for the disk fine surface finished seating for good sealing one seat globe valve two seat gate valve

Valve Stem
Valve stem provides the necessary movement to the disc, plug or the ball one end connected to the actuator second end to disc linear or rotatory movement

Valves by construction type

The valving element rotates in the passageway to stop flow. Eg.: Ball Valve, Butterfly Valve

Valves by construction type

The valving element acts as a 'seal' or 'plug' in the passageway to stop flow. Eg.: Globe Valve

Valves by construction type

The valving element is 'inserted' into the passageway to stop flow. Eg.: Gate Valve

Valves by construction type

The valving element is 'pinched' against the passageway from the outside to stop flow. Eg.: Diaphragm Valve

Ball Valve

Butterfly Valve

Globe Valve

Gate Valve

Diaphragm Valve

Valve - Flow characteristics

Linear, Equal %, quick (fast) opening % flow Vs % opening

Valve - Flow characteristics

based on trim (disc, seat)

Valve Positioner

static friction differential pressure another control system within FCE !!