SC-GCM-64 CM Issue 1 Copyright 2005 Spirax-Sarco Limited

Block 8 Control Applications

Pressure Control Applications Module 8.1

Module 8.1
Pressure Control Applications

The Steam and Condensate Loop

8.1.1

Block 8 Control Applications

Pressure Control Applications Module 8.1

Pressure Control Applications

There are many reasons for reducing steam pressure:
o

Steam boilers are usually designed to work at high pressures in order to reduce their physical
size. Operating them at lower pressures can result in reduced output and carryover of boiler
water. It is, therefore, usual to generate steam at higher pressure.
Steam at high pressure has a relatively higher density, which means that a pipe of a given size
can carry a greater mass of steam at high pressure, than at low pressure. It is usually preferable
to distribute steam at high pressure as this allows smaller pipes to be used throughout most of
the distribution system.
Lower condensing pressures at the point of use tend to save energy. Reduced pressure will
lower the temperature of the downstream pipework and reduce standing losses, and also
reduce the amount of flash steam generated when condensate from drain traps is discharging
into vented condensate collecting tanks.
It is worth noting that if condensate is continuously dumped to waste, perhaps because of the
risk of contamination, less energy will be lost if the condensing pressure is lower.

8.1.2

Because steam pressure and temperature are related, control of pressure can be used to control
temperature in some processes. This fact is recognised in the control of sterilisers and autoclaves,
and is also used to control surface temperatures on contact dryers, such as those found in
papermaking and corrugator machines. Pressure control is also the basis of temperature control
in heat exchangers.
For the same heating duty, a heat exchanger designed to operate on low-pressure steam will
be larger than one designed to be used on high-pressure steam. The low-pressure heat exchanger
might be less expensive because of a lower design specification.
The construction of plant means that each item has a maximum allowable working pressure
(MAWP). If this is lower than the maximum possible steam supply pressure, the pressure must
be reduced so that the safe working pressure of the downstream system is not exceeded.
Many plants use steam at different pressures. A stage system where high-pressure condensate
from one process is flashed to steam for use in another part of the process is usually employed
to save energy. It may be necessary to maintain continuity of supply in the low pressure system
at times when not enough flash steam is being generated. A pressure reducing valve is ideally
suited for this purpose.

The Steam and Condensate Loop

Block 8 Control Applications

Pressure Control Applications Module 8.1

Direct operating, self-acting pressure reducing valve

bellows type
Description

With this self-acting type of pressure controller, the downstream (control) pressure is balanced
(via a bellows) against a spring force.

Advantages:
1.
2.
3.
4.
5.
6.

Inexpensive.
Small.
Easy to install.
Very robust, giving long life with minimum maintenance.
Tolerant of imperfect steam conditions.
Self-acting principle means that no external power is required.

Disadvantages:

1. Proportional only control.

2. Proportional band is 30% to 40% of the upstream pressure.
3. Wide proportional band means that maximum flow is only achieved when the downstream
pressure has dropped considerably. This means that the reduced pressure will vary depending
on flowrate.
4. Limited in size.
5. Limited flowrate.
6. Variation in upstream pressure will result in variation in downstream pressure.

Applications:

Non-critical, moderate load applications with constant running flowrates, for example:
1. Small jacketed pans.
2. Tracer lines.
3. Ironers.
4. Small tanks.
5. Acid baths.
6. Small storage calorifiers.
7. Unit heaters.
8. Small heater batteries.
9. OEM equipment.

Points to note:

1. Different versions for steam, compressed air, and water.

2. Soft seat versions may be available for use on gases.
3. A wide range of body materials means that particular standards, applications and preferences
can be satisfied.
4. A wide proportional band means care is needed if the safety valve needs to be set close to the
working pressure.

High pressure
steam in

Separator

Pressure
reducing
valve

Safety valve

Low pressure
steam out

Condensate
Fig. 8.1.1 General arrangement of a direct operating, self-acting pressure reducing station

The Steam and Condensate Loop

8.1.3

Block 8 Control Applications

Pressure Control Applications Module 8.1

Direct operating, self-acting pressure reducing valve

diaphragm type
Description:

With this self-acting type of pressure controller, the downstream (control) pressure is balanced
(via a diaphragm) against a spring force.

Advantages:
1.
2.
3.
4.
5.
6.
7.

Very robust.
Tolerant to wet and dirty steam.
Available in large sizes, so high flowrates are possible.
Easy to set and adjust.
Simple design means easy maintenance.
Self-acting principle means that no external power is required.
Able to handle pressure drops of 50:1 in small sizes, and 10:1 in large sizes.

Disadvantages:

1. Large proportional band means that close control of downstream pressure is improbable with
large changes in load.
2. Relatively high purchase cost, but lifetime cost is low.
3. Bulky.

Applications:

1. Distribution mains.
2. Boiler houses.

Points to note:

1. Because the diaphragm is subject to fairly low temperature limitations, a water seal is required
on steam applications. This adds to the cost slightly.
2. Because of the large proportional band, this type of valve is better suited to reducing steam
pressure to plant areas rather than individual plant items.
3. A bellows sealed stem ensures zero maintenance and zero emissions.
4. Although wide proportional band provides stability, care is needed if a safety valve needs to
be set close to the apparatus working pressure.
5. Suitable for liquid applications.
6. More expensive than a pilot operated valve, but less expensive than a pneumatic control
system.
Safety valve

High pressure
steam in

Condensate

Separator

Low pressure
steam out

Pressure
reducing
valve

Fig. 8.1.2 General arrangement of a direct operating, self-acting pressure reducing station

8.1.4

The Steam and Condensate Loop

Block 8 Control Applications

Pressure Control Applications Module 8.1

Pilot operated, self-acting pressure reducing valve

Description

These have a more complex self-acting design, and operate by sensing the downstream pressure
via a pilot valve, which in turn operates the main valve.
The effect is a very narrow proportional band, typically less than 200 kPa.
This, together with low hysterisis, results in very tight and repeatable control of pressure, even
with widely varying flowrates.

Advantages:

1. Accurate and consistent pressure control, even at high and variable flowrates.
2. A variety of pilot valves may be used on one main valve. Pilot valve options include electrical
override, multi-pilot for a choice of control pressures, a surplussing option and remote control,
as well as different temperature / pressure control combinations.
3. Self-acting principle means that no external power is required.
4. Tolerant of varying upstream pressure.

Disadvantages:

1. More expensive than bellows operated direct acting controls.

2. Small clearances mean that steam must be clean and dry to ensure longevity, but this can be
achieved by fitting a strainer and separator before the pressure reducing valve.

Applications:

1. A system which requires accurate and consistent pressure control, and installations which
have variable and medium flowrates. For example: autoclaves, highly rated plant such as
heat exchangers and calorifiers.
2. A system where installation space is limited.

Points to note:

1. Installation must include a strainer and separator.

2. Size for size, pilot operated valves are more expensive than bellows type self-acting controls,
but cheaper than diaphragm type self-acting controls.
3. Size for size, they have higher capacity than bellows type self-acting controls, but less than
diaphragm type self-acting controls.
4. Can be installed before temperature control valves to maintain a constant upstream pressure,
and hence stabilise control.
5. Not suitable for liquid applications.
6. Do not use if the plant is subject to vibration, or other equipment is causing pulses in flow.
Pressure
reducing
valve
High pressure
steam in

Separator

Safety valve

Low pressure
steam out

Condensate
Fig. 8.1.3 General arrangement of a pilot operated, self-acting pressure reducing station

The Steam and Condensate Loop

8.1.5

Block 8 Control Applications

Pressure Control Applications Module 8.1

Pressure reduction pneumatic

Description:

These control systems may include:

o

P + I + D functions to improve accuracy under varying load conditions.

Set point(s), which may be remotely adjusted.

Advantages:
1.
2.
3.
4.
5.
6.
7.

Very accurate and flexible.

No limit on valve size within the limits of the valve range.
Acceptable 50:1 flow rangeability (typically for a globe control valve).
Suitable for hazardous environments.
No electrical supply required.
Fast operation means they respond well to rapid changes in demand.
Very powerful actuation being able to cope with high differential pressures across the valve.

Disadvantages:

1. More expensive than self-acting controls.

2. More complex than self-acting controls.
3. Not directly programmable.

Applications:

A system which requires accurate and consistent pressure control, and installations which have
variable and high flowrates and / or variable or high upstream pressure. For example: autoclaves,
highly rated plant such as large heat exchangers and calorifiers.

Points to note:

1. A clean, dry air supply is required.

2. A skilled workforce is required to install the equipment, and instrument personnel are required
for calibration and commissioning.
3. The control is stand-alone, and cannot communicate with PLCs (Programmable Logic
Controllers).
4. The failure mode can be important. For example, a spring-to-close on air failure is normal on
steam systems.
Pneumatic
pressure
reducing
valve

High pressure
steam in

Separator

Low pressure
steam out

Safety
valve

Condensate
Pneumatic controller
Fig. 8.1.4 General arrangement of a pneumatic pressure reducing station

8.1.6

The Steam and Condensate Loop

Block 8 Control Applications

Pressure Control Applications Module 8.1

Pressure reduction electropneumatic

Description

These control systems may include:

o

P + I + D functions to improve accuracy under varying load conditions.

Set point(s) which may be remotely adjusted, with the possibility of ramps between set points.

Advantages:
1.
2.
3.
4.
5.
6.

Very accurate and flexible.

Remote adjustment and read-out.
No limit on valve size within the limits of the valve range.
Acceptable 50:1 flow rangeability (typically for a globe control valve).
Fast operation rapid response to changes in demand.
Very powerful actuation being able to cope with high differential pressures across the valve.

Disadvantages:

1. More expensive than self-acting or pneumatic controls.

2. More complex than self-acting or pneumatic controls.
3. Electrical control signal required. Costly for hazardous areas.

Applications:

A system which requires accurate and consistent pressure control, and installations which have
variable and high flowrates and/or variable or high upstream pressure, including autoclaves, highly
rated plant such as large heat exchangers and calorifiers, and main plant pressure reducing stations.

Points to note:

1. A clean, dry air supply is required.

2. A skilled workforce is required to install the equipment, and instrument personnel are required
for calibration and commissioning.
3. Can be part of a sophisticated control system involving PLCs, chart recorders and SCADA
systems.
4. Always consider the failure mode, for example, spring-to-close on air failure is normal on
steam systems.
Electronic
controller

Pneumatic
pressure
reducing
valve

High pressure
steam in

Separator
Safety
valve

Low pressure
steam out
Pressure
transmitter

Condensate
Fig. 8.1.5 General arrangement of an electropneumatic pressure reducing station

The Steam and Condensate Loop

8.1.7

Block 8 Control Applications

Pressure Control Applications Module 8.1

Pressure reduction electric

Description:

These control systems may include:

o

P + I + D functions to improve accuracy under varying load conditions.

Set point(s), which may be remotely adjusted.

Advantages:

1. Both controller and valve actuator can communicate with a PLC.

2. No compressed air supply is required.

Disadvantages:

1. If a spring return actuator is required, the available shut-off pressure may be limited.
2. Relatively slow actuator speed, so only suitable for applications where the load changes slowly.

Applications:

1. Slow opening / warm-up systems with a ramp and dwell controller.

2. Pressure control of large autoclaves.
3. Pressure reduction supplying large steam distribution systems.

Points to note:

1. Safety: If electrical power is lost the valve position cannot change unless a spring return
actuator is used.
2. Spring return actuators are expensive and bulky, with limited shut-off capability.
Electronic
controller
Electronic
pressure
reducing
valve
Safety
valve

High pressure
steam in

Separator

Low pressure
steam out
Pressure
transmitter

Condensate
Fig. 8.1.6 General arrangement of an electric pressure reducing station

8.1.8

The Steam and Condensate Loop

Block 8 Control Applications

Pressure Control Applications Module 8.1

Pressure reduction (other possibilities)

Parallel pressure reducing stations
Description:

Pressure reducing stations may be configured as shown below for one of two reasons:
1. The valves are serving a critical application for which downtime is unacceptable
The equipment is operated on a one in operation, one on stand-by basis to cover for breakdown
and maintenance situations
2. The turndown ratio between the maximum and minimum flowrates is very high
The equipment is operated on a pressure sequence principle with one valve set at the ideal
downstream pressure, and the other at a slightly lower pressure.
When demand is at a maximum, both valves operate; when flow is reduced, the valve set at the
lower pressure shuts off first, leaving the second valve to control.

Point to note:

The valves selected for this type of application will require narrow proportional bands (such as
pilot operated pressure reducing valves or electro-pneumatic control systems) to avoid the
downstream pressure dropping too much at high flow rates.
Pressure
reducing
valve

Pressure
reducing
valve
High pressure
steam in

Safety
valve

Safety
valve

Separator

Low pressure
steam out

Condensate
Fig. 8.1.7 Parallel pressure reducing station

The Steam and Condensate Loop

8.1.9

Block 8 Control Applications

Pressure Control Applications Module 8.1

Pressure reduction (other possibilities)

Series pressure reducing stations
A pressure reducing station may be configured in this manner if the ratio between the
upstream and downstream pressure is very high, and the control systems selected have a low
turndown ability. 10:1 is recommended as a practical maximum pressure ratio for this type of
reducing valve.
Consider the need to drop pressure from 25 bar g to 1 bar g. The primary reducing valve might
reduce pressure from 25 bar g to 5 bar g, which constitutes a pressure ratio of 5:1. The secondary
reducing valve would drop pressure from 5 bar g to 1 bar g, also 5:1. Both valves in series provide
a pressure ratio of 25:1.
It is important to check the allowable pressure turndown ratio on the selected reducing valve, this
may be 10:1 on a self-acting valve, but can be much higher on electrically or pneumatically
operated valves. Be aware that high pressure drops might have a tendency to create high noise
levels. Refer to Module 6.4 for further details.

Pilot operated
reducing valves
High pressure
steam in

Pilot operated
reducing valves

Safety
valve

Separator

Low pressure
steam out
Trapping
point
Condensate

Condensate

Fig. 8.1.8 Typical series pressure reducing station

The trapping point between the two reducing valves (Figure 8.1.8) is to stop a build up of
condensate under no-load conditions. If this were not fitted, radiation losses would cause
condensate to fill the connecting pipe, which would cause waterhammer the next time the
load increased.

8.1.10

The Steam and Condensate Loop

Block 8 Control Applications

Pressure Control Applications Module 8.1

Desuperheaters
Desuperheating is the process by which superheated steam is either restored to its
saturated state, or its superheated temperature is reduced. Further coverage of desuperheaters is
given in Block 15.
The system in Figure 8.1.9 illustrates an arrangement of a pressure reducing station with a
direct contact type pipeline desuperheater.
In its basic form, good quality water (typically condensate) is directed into the superheated steam
flow, removing heat from the steam, causing a drop in the steam temperature.
Pressure
controller

Good quality water in

Pressure
control
valve

Temperature
control valve

Superheated
steam in
Desuperheater
unit

Temperature
controller

PT100
temperature
Pressure
sensor
transmitter

Steam out

Fig. 8.1.9 Simple steam atomising desuperheater station

It is impractical to reduce the steam temperature to its saturated value, as the control system is
unable to differentiate between saturated steam and wet steam at the same temperature.
Because of this, the temperature is always controlled at a value higher than the relevant saturation
temperature, usually at 5C to 10C above saturation.
For most applications, the basic system as shown in Figure 8.1.9 will work well. As the downstream
pressure is maintained at a constant value by the pressure control loop, the set value on the
temperature controller does not need to vary; it simply needs to be set at a temperature slightly
above the corresponding saturation temperature.
However, sometimes a more complex control system is required, and is shown in Figure 8.1.10.
Should there be a transient change in the superheated steam supply pressure, or a change in the
water supply temperature, the required water/steam flow ratio will also need to change.
A change in the water/steam flow ratio will also be required if the downstream pressure changes,
as is sometimes the case with certain industrial processes.

The Steam and Condensate Loop

8.1.11

Block 8 Control Applications

Pressure Control Applications Module 8.1

Pressure
controller

Good quality water in

Saturation
temperature
computer
Pressure
control
valve

Temperature
control
valve

Temperature
controller

Superheated
steam in
Desuperheater
unit

PT100
temperature
sensor Pressure
transmitter

Steam out

Fig. 8.1.10 Steam atomising desuperheater station with downstream pressure / temperature compensation

The system shown in Figure 8.1.10 works by having the pressure controller set at the required
downstream pressure and operating the steam pressure control valve accordingly.
The 4-20 mA signal from the pressure transmitter is relayed to the pressure controller and the
saturation temperature computer, from which the computer continuously calculates the saturation
temperature for the downstream pressure, and transmits a 4-20 mA output signal to the temperature
controller in relation to this temperature.
The temperature controller is configured to accept the 4-20 mA signal from the computer to
determine its set point at 5C to 10C above saturation. In this way, if the downstream pressure
varies due to any of the reasons mentioned above, the temperature set point will also automatically
vary. This will maintain the correct water/steam ratio under all load or downstream pressure
conditions.

8.1.12

The Steam and Condensate Loop

Block 8 Control Applications

Pressure Control Applications Module 8.1

Controlling pressure to control temperature

Description

These are applications which utilise the predictable relationship between saturated steam pressure
and its temperature.

Advantages:

1. The pressure sensor may be located in the steam space, or close to the control valve rather
than in the process medium itself. This is an advantage where it is difficult to measure the
process temperature.
2. This arrangement can be used to control a number of different elements from a single point.

Disadvantage:

1. Control is open loop, in that the sensor is not measuring the actual product temperature.

Applications:

1. Autoclaves and sterilisers

2. Presses and calenders
3. Constant pressure plant, for example, jacketed pans, unit heaters, and steam-jacketed pipes.

Point to note:

Good air venting is essential (refer to Module 11.12 for further details)
Safety valve

High pressure
supply

Separator

Pilot
operated
pressure reducing
valve

Condensate

Low pressure to autoclave

Automatic air vent

Autoclave
Fig. 8.1.11 Pressure control of an autoclave
Condensate

Pilot operated pressure

reducing valve

Condensate
Automatic air vent

High pressure
supply

Jacketed pipe

Fig. 8.1.12 Pressure control on a jacketed pipe application

The Steam and Condensate Loop

Jacketed pipe

Condensate

Condensate

8.1.13

Block 8 Control Applications

Pressure Control Applications Module 8.1

Safety valve

High pressure
supply

Multi-platen
press
Pilot operated pressure
reducing valve with on-off
function
Low pressure
to press

Condensate
Fig. 8.1.13 Pressure control on a multi platen press

Safety
valve

Direct acting
pressure reducing
valve

Automatic
air vent

Jacketed pan

High pressure
steam supply

Condensate
Fig. 8.1.14 Pressure / temperature control on a jacketed pan

Pilot
operated
pressure
reducing
valve

Electropneumatic
control system
Flow

High pressure supply

Return
Condensate
Fig. 8.1.15 Constant pressure steam supply to a control valve supplying a plate heat exchanger

8.1.14

The Steam and Condensate Loop

Block 8 Control Applications

Pressure Control Applications Module 8.1

Differential pressure control

Description

In these applications the control valve will open and close to maintain a set differential pressure
between two points.

Advantages:

1. A constant differential steam pressure is maintained in the system.

2. The differential pressure ensures that condensate is actively purged from the heat exchange
system. This is particularly important where accumulated condensate could act as a heat
barrier, and create a temperature gradient across the heat transfer surface.
This temperature gradient could, in turn, result in a distorted or poorly heated product.
3. Different operating temperatures can be achieved.

Disadvantage:

A complex system is required if efficiency is to be maintained. This might involve flash

vessels and/or thermo-compressors, as well as downstream applications which use the
lower pressure pass-out steam.

Application:

Blow-through drying rolls in a paper mill.

Point to note:

A special controller or differential pressure transmitter is required to accept two inputs; one
from the primary steam supply and the other from the flash vessel. In this way, the pressure
differential between the flash vessel and the primary steam supply is maintained under all
load conditions.
High pressure
steam in

Condensate
Differential
pressure
controller
Pneumatic
pressure
reducing
valve

Flash vessel
High pressure condensate discharging into a flash vessel
Fig. 8.1.16 Differential pressure control

The Steam and Condensate Loop

Condensate

8.1.15

Block 8 Control Applications

Pressure Control Applications Module 8.1

Surplussing control
Description

The objective is to maintain the pressure upstream of the control valve. Surplussing valves are
discussed in further detail in Module 7.3, Self-acting pressure controls and applications.

Applications:

1. Boilers on plants where the load can change by a large proportion over a very short period.
The sudden reduction in boiler pressure may result in increased turbulence and rapid flashing
of the boiler water, and large quantities of water being carried over into the pipework system.
2. Accumulators where surplus boiler output is used to heat a mass of water under pressure.
This stored energy is then released when the boiler has insufficient capacity.

Points to note:

1. Minimum pressure drop is usually required over the fully open control valve; this may mean
a line size valve is needed.
2. Not all self-acting controls are suitable for this application and it is important to consult the
manufacturer before use.
Surplussing valve

Dry steam at all times

Condensate

Fig. 8.1.17 Surplussing control on a steam boiler

Surplussing
valve

Steam from boiler

Pneumatic
pressure
reducing
valve

Steam to plant

Overflow
Accumulator
Fig. 8.1.18 Steam accumulator

8.1.16

Drain (normally closed)

The Steam and Condensate Loop

Block 8 Control Applications

Pressure Control Applications Module 8.1

Cascade control Limiting pressure and temperature

with one valve
Description

Where it is necessary to control two variables with one valve it is necessary to employ two
separate controllers and sensors. It is always the case that the control valve accepts its control
signal from the slave controller.
The slave controller is configured to accept two input signals, and its set point will change (within
defined limits) depending on the electrical output signal from the master controller.
This form of control is very important where the pressure to the apparatus must be limited,
despite the heat demand.

Application:

The steam heated plate heat exchanger shown in Figure 8.1.19 is heating water circulating in a
secondary system. The heat exchanger has a maximum working pressure, consequently this is
limited to that value in the slave controller.
In order to control the secondary water temperature, a master controller and temperature
transmitter monitors the heat exchanger outflow temperature and sends a 4-20 mA signal to the
slave controller, which is used to vary the slave set point, between pre-determined limits.

Points to note:

1. An adequate pressure margin must exist between the set pressure of the safety valve and the
pressure limitation imposed by the controller.
2. The safety valve must not be used as a device to limit pressure in the heat exchanger; it must
only be used as a safety device.
Slave
Master
controller 4-20 mA controller

4-20 mA

Pneumatic
pressure
control
valve

Safety
valve

Steam in
Pressure
sensor

Flow
Temperature
sensor
Return

Condensate

Pump trap
Fig. 8.1.19 Cascaded controllers on the steam supply to a heat exchanger

The Steam and Condensate Loop

8.1.17

Block 8 Control Applications

Pressure Control Applications Module 8.1

Cascade control Combined pressure reduction and

surplussing with one valve
Description

The objective is to reduce steam pressure but not at the expense of overloading the available
supply capacity.

Application:

The upstream pipework is a high-pressure distribution pipe possibly from a distribution manifold
or steam boiler supplying plant of a non-essential nature (Figure 8.1.20). Should the demand be
higher than the supply capacity, the valve closes and throttles the steam flow, maintaining the
pressure in the upstream pipework.
The master controller is set at the normal expected supply pressure. If the master detects a drop
in upstream pressure below its set value (due to an increase in demand) it reduces the set point
in the slave controller, in proportion to pre-determined limits.
The slave closes the valve until the steam demand falls to allow the upstream pressure to
re-establish to the required value. When this is achieved, the set point of the slave controller is
set at its original value.

Master
controller

Slave
controller

4-20 mA

4-20 mA

Steam flow

High
pressure

Reducing / surplussing valve

Low
pressure

Fig. 8.1.20 General schematic arrangement of a reducing / surplussing valve

Typical settings

The output from the master controller is direct acting, that is, when the upstream pressure is at or
above its proportional band, the masters output signal is maximum at 20 mA; when at the
bottom of, or below the proportional band, the control signal is minimum at 4 mA.
When the control signal is 20 mA, the slave set point is the required downstream pressure; when
the signal is 4 mA, the slave set point is at a pre-determined minimum.
Consider the normal upstream pressure to be 10 bar g, and the maximum allowable
downstream pressure to be 5 bar g. The minimum allowable upstream pressure is 8.5 bar g,
which means that if this pressure is reached the valve is fully shut. The minimum reduced
pressure is set at 4.6 bar g.
These conditions are recorded in Table 8.1.1
Table 8.1.1
P1
bar g
10.0
9.5
9.0
8.5
8.0

8.1.18

P1 and Master
output signal
Output signal

Upstream pressure

Master output signal Master output signal

mA
and slave set point
20
Output signal
20
12
4
Slave set point
4

Slave set point

bar g
5.0
5.0
4.8
4.6
4.6

The Steam and Condensate Loop

Block 8 Control Applications

Pressure Control Applications Module 8.1

Cascade control Limiting and controlling temperature

with one valve
Description

The main objective is to limit and regulate the temperature to a particular process, where
steam is the available heat source but it cannot be used directly to heat the final product for
operational reasons.

Application:

A typical application is a dairy cream pasteuriser requiring a pasteurisation temperature of 50C.

Because of the low control temperature, if steam were applied directly to the pasteurisation heat
exchanger, it is possible that the relatively large amount of heat in the steam would make control
difficult, causing the system temperatures to oscillate, overheating and spoiling the cream.
To overcome this problem, the system in Figure 8.1.21 shows two heat exchangers. The pasteuriser
is heated by hot water supplied from the primary steam heated heat exchanger.
However, even with this arrangement, if only the master controller operated the valve, a time lag
would be introduced into the system, and poor control might again be the result.
Two controllers are therefore used, working in cascade, each receiving a 4-20 mA signal from
their respective temperature transmitters.
The slave controller is used to control the final temperature of the product within clearly defined
limits (perhaps between 49C and 51C). These values are altered by the master controller relative
to the product temperature such that, if the product temperature increases, the slave set point
reduces in proportion.
Master
4-20 mA

Slave
Temperature sensor
Steam flow

Temperature sensor
Cream flow

Water

Steam / water heat exchanger

Pasteuriser

Cream return

Condensate
Fig. 8.1.21 Schematic diagram showing a pasteuriser control using the cascade principle

The Steam and Condensate Loop

8.1.19

Block 8 Control Applications

Pressure Control Applications Module 8.1

Questions
1. What is MAWP?
a| Maximum attenuated working pressure

b| Minimum allowable working pressure

c| Maximum allowable with pressure

d| Maximum allowable working pressure

2. One large and one small steam-heated heat exchanger have exactly the same
heating duty. Which will operate at the lower pressure?
a| The smaller one

b| The larger one

c| They will both operate at the same pressure

d| There is not enough information to answer the question

3. Name one disadvantage of a direct acting pressure reducing valve

a| It only has proportional control

b| It has proportional and integral control but no derivative control

c| It operates in an on / off fashion

d| An external power source is required for it to operate

4. What type of pressure reducing station is required when the pressure ratio
is greater than 10:1
a| A parallel station

b| A pilot operated station

c| A series station

d| A surplussing station

5. Why is cascade control used?

a| To control the flow of water over a weir

b| When more than one input is necessary to secure good control

c| When more than one valve is required to secure control

d| When two pressures are being sampled

6. Why is it sometimes necessary to reduce pressure?

a| To increase the pipe size

b| Because the apparatus pressure is lower than the supply pressure

c| Because the boiler pressure is too high

d| To increase the steam flowrate

Answers

1: d, 2: b, 3: a, 4: c, 5: b, 6: b

8.1.20

The Steam and Condensate Loop