Instrumentation Process

Control System Instrumentation

Lecture December 31, 2014

Dr Edi Munawar
Dr.
Chemical Engineering Department
Syiah Kuala University
Contact: edi.munawar@che.unsyiah.ac.id
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Control System Instrumentation

A typical process transducer:

General configuration of a measurement transducer, it

typically consists of a sensing element combined with a
driving element (transmitter).

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Control System Instrumentation

Transducers for process measurements convert the
magnitude
g
of a pprocess variable ((e.g.
g flow rate,,
pressure, temperature, level, or concentration) into a
signal that can be sent directly to the controller.
The sensing element is required to convert the
measured quantity, that is, the process variable, into
some quantity more appropriate for mechanical or
electrical processing within the transducer.

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Control System Instrumentation

Before 1960, instrumentation in the process
industries utilized p
pneumatic ((air ppressure)) signals
g
to
transmit measurement and control information
almost exclusively.
These devices make use of mechanical force-balance
elements to generate signals in the range of 3 to 15
psig, an industry standard.
Since about 1960, electronic instrumentation has
come into widespread use.

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Sensors
A sensor is a device that detects events or changes in
quantities and pprovides a corresponding
q
p
g output,
p ,
generally as an electrical or optical signal; for
example, a thermocouple converts temperature to an
output voltage.

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Transmitters
A transmitter usually converts the sensor output to a
signal
g level appropriate
pp p
for input
p to a controller,, such
as 4 to 20 mA.
Transmitters are generally designed to be direct
acting.
In addition, most commercial transmitters have an
djus b e input
pu range
ge (o
(or sp
span).
).
adjustable
For example, a temperature transmitter might be
adjusted so that the input range of a platinum
resistance element (the sensor) is 50 to 150 C
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Transmitters
In this case, the following correspondence is
obtained
Input
50 C
150 C

Output
4 mA
20 mA

This instrument (transducer) has a lower limit or

zero off 50 C andd a range or span off 100 C

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Transmitters
For the temperature transmitter discussed above, the
relation between transducer output
p and input
p is:

20 4mA
o
Tm (mA)
T 50 C 4mA
o
150 50 C

mA T C 4mA
0.16
C
o

The gain of the measurement element Km is 0.16

mA/C. For any linear instrument:

Km
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range of instrument output

range of instrument input

(9.1)
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Final Control Elements

Every process control loop contains a final control
element ((actuator),
), the device that enables a pprocess
variable to be manipulated.
For most chemical and petroleum processes, the final
control elements (usually control valves) adjust the
flow rates of materials, and indirectly, the rates of
energy transfer to and from the process.

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Final Control Elements

A linear instrument calibration showing its zero and
span.
p

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Control Valves
There are many different ways to manipulate the
flows of material and energy
gy into and out of a
process; for example, the speed of a pump drive,
screw conveyer, or blower can be adjusted.
However, a simple and widely used method of
accomplishing this result with fluids is to use a
control valve
valve, also called an automatic control valve.
valve
The control valve components include the valve
body, trim, seat, and actuator.
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Air-to-Open vs. Air-to-Close Control

Valves
Normally, the choice of A-O or A-C valve is based
on safety
y considerations.

A pneumatic control valve (air-to-open)

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Air-to-Open vs. Air-to-Close Control

Valves

A pneumatic control valve

(air-to-open)

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A pneumatic control valve

(air-to-close)

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Specifying and Sizing Control

Valves
A design equation used for sizing control valves is:

q Cv f l

Pv
gs

(9.2)

where:
q : flow rate (gal/min)
Cv : proportionality factor that depends predominantly
on valve size or capacity (unit less).
f l : flow characteristic (unit less).
P : pressure drop across the valve (psig)
gs : specific gravity of the fluid
This relation is valid for nonflashing fluids.
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Specifying and Sizing Control

Valves
Specification of the valve size is dependent on the socalled valve characteristic f.
Three control valve characteristics are mainly used.
For a fixed pressure drop across the valve, the flow
characteristic f (0 f 1) is related to the lift l (0 l
1), that is the extent of valve opening, by one of the
following relations:
Linear
: f l
Quick opening
: f l
Equal percentage : f R l 1
where R is a valve design parameter that is usually in the
range of 20 to 50.
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Specifying and Sizing Control

Valves

Control valve characteristics

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Specifying and Sizing Control

Valves
Rangeability
The rangeability
g
y of a control valve is defined as the
ratio of maximum to minimum input signal level.
For control valves, rangeability translates to the need
to operate the valve within the range 0.05 f 0.95
or a rangeability of 0.95/0.05 = 19.

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Specifying and Sizing Control

Valves
To Select an Equal Percentage Valve:
a)) Plot the pump
p p characteristic curve and PS, the
system pressure drop curve without the valve, as
shown in Fig. below.

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Specifying and Sizing Control

Valves
The difference between these two curves is Pv.
The p
pump
p should be sized to obtain the desired
value of Pv Ps . For example, 25 to 33%, at the
design flow rate qd.
b) Calculate the valves rated Cv, the value that
yields at least 100% of qd with the available
pressure drop at that higher flow rate.
rate

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Specifying and Sizing Control

Valves
c) Compute q as a function of l using Eq. 9.2, the
rated Cv, and Pv from ((a).
) Ap
plot of the valve
characteristic (q vs. l) should be reasonably linear
in the operating region of interest (at least around
the design flow rate). If it is not suitably linear,
adjust the rated Cv and repeat

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Specifying and Sizing Control

Valves
Example
Ap
pump
p furnishes a constant head of 40 ppsi over the
entire flow rate range of interest. The heat exchanger
pressure drop is 30 psig at 200 gal/min (qd) and can
be assumed to be proportional to q2. Select the rated
Cv of the valve and plot the installed characteristic
for the following case a linear valve that is half open
at the design flow rate

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Specifying and Sizing Control

Valves
Solution

A control valve placed in series with a pump and a heat

exchanger. Pump discharge pressure is constant
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Specifying and Sizing Control

Valves
1) We write an expression for the pressure drop across
the heat exchanger:
g

Phe q

30 200

(9.3)
2

q
PS Phe 30

(9.4)
200
2) Because the pump head is constant at 40 psi, the
pressure drop available for the valve is:
2
q
(9.5)
Pv 40 Phe 40 30

200
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Specifying and Sizing Control

Valves
1) Figure below illustrates these relations. Note that in
all four design
g casesPv Ps 10 30 33% at qd.:

Pump characteristic and system pressure drop

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Specifying and Sizing Control

Valves
3) Calculate the rated Cv :

Cv

200
126.5
0.5 10

((9.6))

We will use Cv = 125. For a linear characteristic

valve, use the relation between l and q from Eq. 9.2:

q
Cv Pv

(9.7)

Using Eq. 9.7 and values of Pv from Eq. 9.5, the

installed valve characteristic curve can be plotted:
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Specifying and Sizing Control

Valves

Installed valve characteristics

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Next Lecture

Thank you for your

attention and Happy New
Year 2015
Edi Munawar

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