SOLENOID VALVE

A solenoid valve is an electromechanically operated valve. The valve is controlled by

an electric current through a solenoid: in the case of a two-port valve the flow is switched on
or off; in the case of a three-port valve, the outflow is switched between the two outlet ports.
Multiple solenoid valves can be placed together on a manifold. Solenoid valves are the most
frequently used control elements in fluidics. Their tasks are to shut off, release, dose,
distribute or mix fluids. They are found in many application areas. Solenoids offer fast and
safe switching, high reliability, long service life, good medium compatibility of the materials
used, low control power and compact design. Besides the plunger-type actuator which is used
most frequently, pivoted-armature actuators and rocker actuators are also used.
OPERATION
There are many valve design variations. Ordinary valves can have many ports and
fluid paths. A 2-way valve, for example, has 2 ports; if the valve is open, then the two ports
are connected and fluid may flow between the ports; if the valve is closed, then ports are
isolated. If the valve is open when the solenoid is not energized, then the valve is termed
normally open (N.O.). Similarly, if the valve is closed when the solenoid is not energized,
then the valve is termed normally closed. There are also 3-way and more complicated
designs. A 3-way valve has 3 ports; it connects one port to either of the two other ports
(typically a supply port and an exhaust port). Solenoid valves are also characterized by how
they operate. A small solenoid can generate a limited force. If that force is sufficient to open
and close the valve, then a direct acting solenoid valve is possible. An approximate
relationship between the required solenoid force F
s
, the fluid pressure P, and the orifice
area A for a direct acting solenoid value is:

Where d is the orifice diameter. A typical solenoid force might be 15 N (3.4 lb
f
). An
application might be a low pressure (e.g., 10 pounds per square inch (69 kPa)) gas with a
small orifice diameter (e.g.,
3

8
in (9.5 mm) for an orifice area of 0.11 sq in (7.110
5
m
2
) and
approximate force of 1.1 lbf (4.9 N)). When high pressures and large orifices are
encountered, then high forces are required. To generate those forces, an internally
piloted solenoid valve design may be possible. In such a design, the line pressure is used to
generate the high valve forces; a small solenoid controls how the line pressure is used.
Internally piloted valves are used in dishwashers and irrigation systems where the fluid is
water, the pressure might be 80 pounds per square inch (550 kPa) and the orifice diameter
might be
3

4
in (19 mm).
In some solenoid valves the solenoid acts directly on the main valve. Others use a
small, complete solenoid valve, known as a pilot, to actuate a larger valve. While the second
type is actually a solenoid valve combined with a pneumatically actuated valve, they are sold
and packaged as a single unit referred to as a solenoid valve. Piloted valves require much less
power to control, but they are noticeably slower. Piloted solenoids usually need full power at
all times to open and stay open, where a direct acting solenoid may only need full power for a
short period of time to open it, and only low power to hold it.
A direct acting solenoid valve typically operates in 5 to 10 milliseconds. The operation time
of a piloted valve depends on its size; typical values are 15 to 150 milliseconds.
[4]

INTERNALLY PILOTED
While there are multiple design variants, the following is a detailed breakdown of a
typical solenoid valve design. A solenoid valve has two main parts: the solenoid and the
valve. The solenoid converts electrical energy into mechanical energy which, in turn, opens
or closes the valve mechanically. A direct acting valve has only a small flow circuit, shown
within section E of this diagram (this section is mentioned below as a pilot valve). In this
example, a diaphragm piloted valve multiplies this small pilot flow, by using it to control the
flow through a much larger orifice. Solenoid valves may use metal seals or rubber seals, and
may also have electrical interfaces to allow for easy control. A spring may be used to hold the
valve opened (normally open) or closed (normally closed) while the valve is not activated.


A-Input side
B-Diaphragm
C-Pressure chamber
D-Pressure relief passage
E-Solenoid
F- Output side
The diagram to the right shows the design of a basic valve, controlling the flow of
water in this example. At the top figure is the valve in its closed state. The water under
pressure enters at A. B is an elastic diaphragm and above it is a weak spring pushing it down.
The diaphragm has a pinhole through its center which allows a very small amount of water to
flow through it. This water fills the cavity C on the other side of the diaphragm so that
pressure is equal on both sides of the diaphragm, however the compressed spring supplies a
net downward force. The spring is weak and is only able to close the inlet because water
pressure is equalized on both sides of the diaphragm.
Once the diaphragm closes the valve, the pressure on the outlet side of its bottom is
reduced, and the greater pressure above holds it even more firmly closed. Thus, the spring is
irrelevant to holding the valve closed.
The above all works because the small drain passage D was blocked by a pin which is
the armature of the solenoid E and which is pushed down by a spring. If current is passed
through the solenoid, the pin is withdrawn via magnetic force, and the water in
chamber C drains out the passage D faster than the pinhole can refill it. The pressure in
chamber C drops and the incoming pressure lifts the diaphragm, thus opening the main valve.
Water now flows directly from A to F.
When the solenoid is again deactivated and the passage D is closed again, the spring
needs very little force to push the diaphragm down again and the main valve closes. In
practice there is often no separate spring; the elastomer diaphragm is molded so that it
functions as its own spring, preferring to be in the closed shape.
From this explanation it can be seen that this type of valve relies on a differential of
pressure between input and output as the pressure at the input must always be greater than the
pressure at the output for it to work. Should the pressure at the output, for any reason, rise
above that of the input then the valve would open regardless of the state of the solenoid and
pilot valve.
COMPONENTS


Example core tubes. Non-magnetic core tubes are used to isolate the fluid from the
coil. The core tube encloses the plugnut, the core spring, and the core. The coil slips over the
core tube; a retaining clip engages the depression near the closed end of the core tube and
holds the coil on the core tube. Solenoid valve designs have many variations and challenges.
Common components of a solenoid valve:
Solenoid subassembly
Retaining clip (a.k.a. coil clip)
Solenoid coil (with magnetic return path)
Core tube (a.k.a. armature tube, plunger tube, solenoid valve tube, sleeve, guide
assembly)
Plugnut (a.k.a. fixed core)
Shading coil (a.k.a. shading ring)
Core spring (a.k.a. counter spring)
Core (a.k.a. plunger, armature)
Core tubebonnet seal
Bonnet (a.k.a. cover)
Bonnetdiaphrambody seal
Hanger spring
Backup washer
Diaphram
Bleed hole
Disk
Valve body
Seat
The core or plunger is the magnetic component that moves when the solenoid is
energized. The core is coaxial with the solenoid. The core's movement will make or break the
seals that control the movement of the fluid. When the coil is not energized, springs will hold
the core in its normal position. The plugnut is also coaxial. The core tube contains and guides
the core. It also retains the plugnut and may seal the fluid. To optimize the movement of the
core, the core tube needs to be nonmagnetic. If the core tube were magnetic, then it would
offer a shunt path for the field lines. In some designs, the core tube is an enclosed metal shell
produced by deep drawing. Such a design simplifies the sealing problems because the fluid
cannot escape from the enclosure, but the design also increases the magnetic path resistance
because the magnetic path must traverse the thickness of the core tube twice: once near the
plugnut and once near the core. In some other designs, the core tube is not closed but rather
an open tube that slips over one end of the plugnut. To retain the plugnut, the tube might be
crimped to the plugnut. An O-ring seal between the tube and the plugnut will prevent the
fluid from escaping.
The solenoid coil consists of many turns of copper wire that surround the core tube and
induce the movement of the core. The coil is often encapsulated in epoxy. The coil also has
an iron frame that provides a low magnetic path resistance.
MATERIALS
The valve body must be compatible with the fluid; common materials are brass,
stainless steel, aluminum, and plastic. The seals must be compatible with the fluid. To
simplify the sealing issues, the plugnut, core, springs, shading ring, and other components are
often exposed to the fluid, so they must be compatible as well. The requirements present
some special problems. The core tube needs to be non-magnetic to pass the solenoid's field
through to the plugnut and the core. The plugnut and core need a material with good
magnetic properties such as iron, but iron is prone to corrosion. Stainless steels can be used
because they come in both magnetic and non-magnetic varieties. For example, a solenoid
valve might use 304 stainless steel for the body, 305 stainless steel for the core tube, 302
stainless steel for the springs, and 430 F stainless steel (a magnetic stainless steel) for the core
and plugnut.
TYPES
Many variations are possible on the basic, one-way, one-solenoid valve described above:
one- or two-solenoid valves;
direct current or alternating current powered
different number of ways and positions
COMMON USES
Solenoid valves are used in fluid power pneumatic and hydraulic systems, to control
cylinders, fluid power motors or larger industrial valves. Automatic irrigation
sprinkler systems also use solenoid valves with an automatic controller. Domestic washing
machines and dishwashers use solenoid valves to control water entry into the machine.
Solenoid valves are used in dentist chairs to control air and water flow. In
the paintball industry, solenoid valves are usually referred to simply as "solenoids." They are
commonly used to control a larger valve used to control the propellant (usually compressed
air or CO
2
). In addition to this, these valves are now being used in household water purifiers
(RO systems). Besides controlling the flow of air and fluids, solenoids are used in
pharmacology experiments, especially for patch-clamp, which can control the application of
agonist or antagonist.
HOW DOES A SOLENOID VALVE WORK?
The solenoid valve uses an electric current which moves the solenoid. This pulls a
piston preventing it from stopping the flow of air and fluid. The valve will need a constant
flow of electrical current to remain open because when there is no current flow, the
electromagnetic field scatters and the valve returns to its original position.
DIFFERENTIAL PRESSURE FLOWMETERS
In a differential pressure drop device the flow is calculated by measuring the pressure drop
over an obstructions inserted in the flow. The differential pressure flowmeter is based on
the Bernoullis Equation, where the pressure drop and the further measured signal is a
function of the square flow speed.

Orifice Plate
With an orifice plate, the fluid flow is measured through the difference in pressure
from the upstream side to the downstream side of a partially obstructed pipe. The plate
obstructing the flow offers a precisely measured obstruction that narrows the pipe and forces
the flowing fluid to constrict.

The orifice plates are simple, cheap and can be delivered for almost any application in
any material. The Turn Down Rate for orifice plates are less than 5:1. Their accuracy are poor
at low flow rates. A high accuracy depend on an orifice plate in good shape, with a sharp
edge to the upstream side. Wear reduces the accuracy.


Venturi Tube
Due to simplicity and dependability, the Venturi tube flowmeter is often used in
applications where it's necessary with higher Turn Down Rates, or lower pressure drops, than
the orifice plate can provide. In the Venturi Tube the fluid flowrate is measured by reducing
the cross sectional flow area in the flow path, generating a pressure difference. After the
constricted area, the fluid is passes through a pressure recovery exit section, where up to 80%
of the differential pressure generated at the constricted area, is recovered.

With proper instrumentation and flow calibrating, the Venturi Tube flowrate can be reduced
to about 10% of its full scale range with proper accuracy. This provides a Turn Down
Rate 10:1.
Flow Nozzles
Flow nozzles are often used as measuring elements for air and gas flow in industrial
applications.

The flow nozzle is relative simple and cheap, and available for many applications in many
materials.
The Turn Down Rate and accuracy can be compared with the orifice plate.
The Sonic Nozzle - Critical (Choked) Flow Nozzle
When a gas accelerate through a nozzle, the velocity increase and the pressure and the gas
density decrease. The maximum velocity is achieved at the throat, the minimum area, where
it breaks Mach 1 or sonic. At this point it's not possible to increase the flow by lowering the
downstream pressure. The flow is choked. This situation is used in many control systems to
maintain fixed, accurate, repeatable gas flow rates unaffected by the downstream pressure.
Recovery of Pressure Drop in Orifices, Nozzles and Venturi Meters. After the pressure
difference has been generated in the differential pressure flow meter, the fluid pass through
the pressure recovery exit section, where the differential pressure generated at the constricted
area is partly recovered.

As we can see, the pressure drop in orifice plates are significant higher than in the venturi
tubes.
Variable Area Flowmeter or Rotameter
The rotameter consists of a vertically oriented glass (or plastic) tube with a larger end at the
top, and a metering float which is free to move within the tube. Fluid flow causes the float to
rise in the tube as the upward pressure differential and buoyancy of the fluid overcome the
effect of gravity.

The float rises until the annular area between the float and tube increases sufficiently
to allow a state of dynamic equilibrium between the upward differential pressure and
buoyancy factors, and downward gravity factors. The height of the float is an indication of
the flow rate. The tube can be calibrated and graduated in appropriate flow units. The
rotameter meter typically have a TurnDown Ratio up to 12:1. The accuracy may be as good
as 1% of full scale rating. Magnetic floats can be used for alarm and signal transmission
functions.
Velocity Flowmeters
In a velocity flowmeter the flow is calculated by measuring the speed in one or more points
in the flow, and integrating the flow speed over the flow area.

Pitot Tubes
The pitot tube are one the most used (and cheapest) ways to measure fluid flow,
especially in air applications as ventilation and HVAC systems, even used in airplanes for the
speed measurent.

The pitot tube measures the fluid flow velocity by converting the kinetic energy of the
flow into potential energy. The use of the pitot tube is restricted to point measuring. With the
"annubar", or multi-orifice pitot probe, the dynamic pressure can be measured across the
velocity profile, and the annubar obtains an averaging effect.
Calorimetric Flowmeter
The calorimetric principle for fluid flow measurement is based on two temperature sensors in
close contact with the fluid but thermal insulated from each other.

One of the two sensors is constantly heated and the cooling effect of the flowing fluid
is used to monitor the flowrate. In a stationary (no flow) fluid condition there is a constant
temperature difference between the two temperature sensors. When the fluid flow increases,
heat energy is drawn from the heated sensor and the temperature difference between the
sensors are reduced. The reduction is proportional to the flow rate of the fluid. Response
times will vary due the thermal conductivity of the fluid. In general lower thermal
conductivity require higher velocity for proper measurement. The calorimetric flowmeter can
achieve relatively high accuracy at low flow rates.
Turbine Flowmeter
There is many different manufacturing design of turbine flow meters, but in general
they are all based on the same simple principle: If a fluid moves through a pipe and acts on
the vanes of a turbine, the turbine will start to spin and rotate. The rate of spin is measured to
calculate the flow. The turndown ratios may be more than 100:1 if the turbine meter is
calibrated for a single fluid and used at constant conditions. Accuracy may be better than +/-
0,1%.
Vortex Flow Meter
An obstruction in a fluid flow creates vortices in a downstream flow. Every
obstruction has a critical fluid flow speed at which vortex shedding occurs. Vortex shedding
is the instance where alternating low pressure zones are generated in the downstream.

These alternating low pressure zones cause the obstruction to move towards the low pressure
zone. With sensors gauging the vortices the strength of the flow can be measured.
Electromagnetic Flowmeter
An electromagnetic flowmeter operate on Faraday's law of electromagnetic induction
that states that a voltage will be induced when a conductor moves through a magnetic field.
The liquid serves as the conductor and the magnetic field is created by energized coils outside
the flow tube. The voltage produced is directly proportional to the flow rate. Two electrodes
mounted in the pipe wall detect the voltage which is measured by a secondary element.
Electromagnetic flowmeters can measure difficult and corrosive liquids and slurries, and they
can measure flow in both directions with equal accuracy. Electromagnetic flowmeters have a
relatively high power consumption and can only be used for electrical conductive fluids as
water.
Ultrasonic Doppler Flowmeter
The effect of motion of a sound source and its effect on the frequency of the sound
was observed and described by Christian Johann Doppler.
The frequency of the reflected signal is modified by the velocity and direction of the fluid flow
If a fluid is moving towards a transducer, the frequency of the returning signal will increase.
As fluid moves away from a transducer, the frequency of the returning signal decrease.
The frequency difference is equal to the reflected frequency minus the originating frequency
and can be use to calculate the fluid flow speed. The Ultrasonic Doppler and Time of Flight
Flowmeter
Positive Displacement Flowmeter
The positive displacement flowmeter measures process fluid flow by precision-fitted
rotors as flow measuring elements. Known and fixed volumes are displaced between the
rotors. The rotation of the rotors are proportional to the volume of the fluid being displaced.
The number of rotations of the rotor is counted by an integral electronic pulse transmitter and
converted to volume and flow rate.
The positive displacement rotor construction can be done in several ways:
Reciprocating piston meters are of single and multiple-piston types. Oval-gear meters have
two rotating, oval-shaped gears with synchronized, close fitting teeth. A fixed quantity of
liquid passes through the meter for each revolution. Shaft rotation can be monitored to obtain
specific flow rates.
Nutating disk meters have moveable disks mounted on a concentric sphere located in
spherical side-walled chambers. The pressure of the liquid passing through the measuring
chamber causes the disk to rock in a circulating path without rotating about its own axis. It is
the only moving part in the measuring chamber.
Rotary vane meters consists of equally divided, rotating impellers, two or more
compartments, inside the meter's housings. The impellers are in continuous contact with the
casing. A fixed volume of liquid is swept to the meter's outlet from each compartment as the
impeller rotates. The revolutions of the impeller are counted and registered in volumetric
units.
The positive displacement flowmeter may be used for all relatively nonabrasive fluids such as
heating oils, lubrication oils, polymer additives, animal and vegetable fat, printing ink, freon,
and many more.
Accuracy may be up to 0.1% of full rate with a TurnDown of 70:1 or more.
Mass Flowmeters
Mass meters measure the mass flow rate directly.
Thermal Flowmeter
The thermal mass flowmeter operates independent of density, pressure, and viscosity.
Thermal meters use a heated sensing element isolated from the fluid flow path where the flow
stream conducts heat from the sensing element. The conducted heat is directly proportional to
the mass flow rate and the he temperature difference is calculated to mass flow.
The accuracy of the thermal mass flow device depends on the calibrations reliability
of the actual process and variations in the temperature, pressure, flow rate, heat capacity and
viscosity of the fluid.
Coriolis Flowmeter
Direct mass measurement sets Coriolis flowmeters apart from other technologies.
Mass measurement is not sensitive to changes in pressure, temperature, viscosity and density.
With the ability to measure liquids, slurries and gases, Coriolis flowmeters are universal
meters.
Coriolis Mass Flowmeter uses the Coriolis effect to measure the amount of mass
moving through the element. The fluid to be measured runs through a U-shaped tube that is
caused to vibrate in an angular harmonic oscillation. Due to the Coriolis forces, the tubes will
deform and an additional vibration component will be added to the oscillation. This
additional component causes a phase shift on some places of the tubes which can be
measured with sensors.
The Coriolis flow meters are in general very accurate, better than +/-0,1% with an
turndown rate more than 100:1. The Coriolis meter can also be used to measure the fluids
density.
Open Channel Flowmeters
A common method of measuring flow through an open channel is to measure the height of
the liquid as it passes over an obstruction as a flume or weir in the channel.

Common used is the Sharp-Crested Weir, the V-Notch Weir, the Cipolletti weir, the
Rectangular-Notch Weir, the Parshall Flume or Venturi Flume.
Weir Flow Measurement Standards - Important and common used standards within
weir flow measurement
Measuring Flow Rate with Weirs - Weirs are often used for measuring flow rates in
open channels and rivers in connection to water supply and sewage plants
















MAKALAH PENGENDALIAN PROSES

CONTROL VALVE AND MEASURE DEVICE














Disusun Oleh :
Muh Aditya Surya Aditama
NIM.1231410116





JURUSAN TEKNIK KIMIA
POLITEKNIK NEGERI MALANG
2014