Ch15 - Industrial Process Techniques

Chapter 15
Industrial Process Techniques and

Instrumentation
Dr. Ammar Hasan

Batch Process
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Batch Process
• A large variety of products, such as beverages,
explosives, pharmaceuticals, liquid detergents,
foods, plastics, and metals are produced by
the batch process method of manufacturing.
• These products are made one batch at a time
and usually in smaller quantities than the
products produced by the continuous method
of manufacturing.
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Example system: Batch Reactor
• In batch processing, a sequence of
steps is performed similar to the way
a food recipe is followed.
• The product is made by putting
ingredients into a vessel, called a
reactor; and then causing them to
react to form a product.
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• During each step in the process, variables must be
controlled. In batch production applications, temperature
and pressure are the two most common variables that
must be regulated to control the rate of reaction.
• Applying thermal energy and maintaining the temperature
at a certain level is critical to most batch processes.
• The type of thermal energy applied, whether it be heating
or cooling, is determined by the type of ingredients used
in the recipe, resulting in an endothermic or an
exothermic reaction
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• In a batch process, exact quantities of raw materials
are required for each batch.
• Measurements can be made by:
• Determining the weight of the ingredients inside the
reactor with a pressure sensor.
• Using a level sensor to read the height of the
ingredients in the vessel.
• Calculating the volumetric flow rate of a raw material
being fed into the reactor by using a flow meter.
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Types of Batch Process
• The four basic categories of batch
processing methods are:
• Mixing/Blending
• Chemical Reaction
• Separation
• Polymerization
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Mixing/Blending
• Some blending operations require precise
control of the time duration for the mixing cycle;
this control is performed by a timer.
• Other types of operations require a precise
speed at which the stirring action takes place to
control the reaction rate.
• A variable speed device is used to control the
rpm at which the motor drives the agitator
blades.
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Chemical Reaction
• A chemical reaction is the process of combining
two or more materials or reactants to form a
product.
• The reaction usually occurs under the influence
of temperature, pressure, agitation, and by
introducing a catalyst.
• A large variety of products, such as fertilizer,
antifreeze, and pesticides, are made by chemical
reaction processes.
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Separation
• A separation operation is opposite to mixing/blending.
During the separation process, an ingredient is
removed from a mixture.
• One example of a separator process is, where acetone
is removed from a mixture of acetone and water
• Over a period of time, some of the acetone will
separate and rise to the top.
• However, the time duration of this process can be
shortened by heating-(or cooling) the mixture.
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Separation
• Another type of separation process is
crystallization.
• Crystallization is the formation of a solid
material item from a solution, vapor,
melted material, or solid that is in a
different phase of the reaction.
• Some types of pharmaceuticals are formed
through this process.
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Polymerization
• Polymerization is a process in which a large
number of molecules are combined to form a
product.
• For polymerization to take place, temperature,
pressure, and a catalyst are supplied under
very precise, controlled conditions.
• Products such as plastics and synthetic
materials are made using this type of process.
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Batch Reactor
All four of these processes occur in a batch reactor. Some
reactors must be made of specific materials. The type of
material used to construct the reactor depends on factors
such as:
• Its capability to withstand the corrosiveness of the
ingredients inside.
• Its capability to not contaminate the contents inside. For
example, stainless steel is often used to hold food products.
• Its capability to withstand the required
temperature/pressure.
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Continuous Process
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Continuous Process
• In a continuous process, raw materials are
continuously passed through manufacturing
equipment at a controlled rate, and the end
product is continuously withdrawn.
• Unlike batch processing, where a relatively
small amount of the product is made,
continuous processing is designed to
manufacture a large volume of a particular
product.
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Continuous Process
• There are several types of continuous process
manufacturing equipment from which products
are formed, such as screens and rollers on a
paper machine, extruders that shape plastic
bags, or an evaporator that processes liquids.
• The stability of the variable must be
maintained, despite changes in process
conditions.
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Continuous Process
• To ensure product quality, several variables must
be continuously controlled simultaneously by
maintaining the process conditions at a constant
set point for each one of them. These include
–Temperature
–Pressure
–Flow
–Level
–Product composition
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Example system: Heat Exchanger
• Heat Exchanger is common in
continuous process.
• A large variety of products, such as
petroleum, chemicals, paper, plastic
garbage bags, and so forth, are
produced by the continuous process
method of manufacturing.
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• It consists of a shell, heads that are removable for
maintenance, a tube section enclosed inside the
shell, and inlet and outlet ports for both the shell and
tube.
• In this configuration, the product flows through the
shell, and the thermal medium from which energy is
obtained flows through the tube.
• Steam or hot water is -usually supplied to the
exchanger-for heating, and cold water is supplied to
the exchanger for cooling.
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Heat blending Process
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Heat blending Process
• shows how other variables can control the
composition of a product.
• Liquid and paste are fed into a chamber, mixed, and
boiled to produce a condensed solution.
• If the solution becomes too concentrated because
the process is altered, the problem can be corrected
by increasing the flow rate of the liquid, by
decreasing the flow rate of the paste, or by reducing
the flow rate of the heat supply that causes boiling to
take place.
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Instruments in
automated systems
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Instrumentation
• As a product is being manufactured, critical
stages of the process must be manipulated
to achieve the desired outcome.
• Modern industrial equipment performs the
manipulation function automatically.
• The control of an industrial process by
automatic rather than manual means is
called automation.
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Block diagram of closed-loop automated system
Final Control
Set Point Process
Controller Element
Variable
(Actuator)
Feedback Measurement
Signal
Measured
Transmitter Value
and/or Sensor
Transducer
Indicator Alarm Recorder
Monitoring Instruments
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Measurement Devices/Sensors
• An industrial process loop begins with
measuring a variable. A control loop is
effective only if the sensor is reliable.
• The reliability of the sensor is affected
by its characteristics, which are
classified as either dynamic or static.
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Measurement Devices/Sensors:
Response Time (Dynamic)
• Sensors do not respond to changes immediately. It takes a period of time
for the sensor to produce the signal that represents the condition that it is
detecting. The term response time is used to describe the amount of time
the sensor takes to respond to a change in the measured variable.
• The response time is determined by several factors, such as the design of
the sensor and the type of variable being measured. For example, flow
and level sensors respond almost immediately to any changes that occur.
• However, temperature sensors take longer because they must physically
heat up or cool down when a temperature change takes place until they
reach the same level as the measured variable. This effect, known as
“temperature lag’ or “thermal lag,” can take from seconds to minutes
when responding to changes.
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• A sensor’s proximity to the measured variable also
affects the response time. For example, a
temperature sensor inside a protection chamber
called a thermowell will take longer to respond than
a sensor directly exposed to the measured medium.
• Similarly, an air pressure sensor inside a pipe will
respond more quickly than an identical sensor
connected to the pipe through a long length of
tubing.
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Accuracy and Precision (Static)
• The term accuracy is used to
describe how closely a sensor
measures the actual value of a
controlled variable
• The term precision is used to
describe how consistently a sensor
responds to the same input value
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Accuracy and Precision (Static)
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Linearity(Static)
• The sensing device converts a physical quantity of the
variable it measures into a signal, such as pneumatic or
electrical.
• With some types of sensing devices, the output
produced is not proportional to the actual condition
measured.
• Instead, the signal produced is the square root of the
variables physical quantity.
• If the input vs. output of the sensor is plotted
graphically, a nonlinear line, or curve, will be produced
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Hysteresis (Static)
• The upward and downward arrows
describe the way in which the output
reading varies as the measured signal
applied to its input increases and
decreases, respectively.
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Sensitivity (Static)
• The sensitivity of a sensor is the ratio of its output change to a
Input change in its input quantity that represents the
measurements.
• A sensor with poor sensitivity will not produce an output
change in response to range of input values. The range is
referred to as dead space.
• The dead space will be smaller for a sensor with better
sensitivity.
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Transmitters
• The different variables that are monitored in the
process industry and the many conditions under which
they are measured require a large variety of sensors to
perform this function.
• Sensors are primarily mechanical devices or electronic
instruments, and they produce many types of signals
that represent the condition of the controlled variable.
• For example, they provide a mechanical movement, a
varying current flow, a voltage, a varying resistance, or
a varying capacitance.
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Transmitters
• These outputs are sent to a transmitter, which has two functions.
• First, it converts a signal from the sensor into a standardized signal
used in process systems.
• Second, since the sensor is often positioned at a remote location
from the controller, it carries the signal the distance between them.
• Some sensors produce very small voltages no greater than 1 mV.
• The transmitter contains an amplifier which boosts the signal high
enough to overcome the resistance of long wires.
• Some transmitters have a signal filtering function as well, such as
low pass filter to remove high frequency noise.
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Transmitters
• The most common types of standard signals are
transmitted electronically, pneumatically, and optically.
• Electronic and pneumatic signals are referred to as
analog because their values are proportional to the
conditions they represent within a standard range.
• Optical signals are referred to as digital signals because
they are either in the “on” or “off” state condition.
• In order to represent specific values, a series of on and
off pulses are optically transmitted. Each value is
represented by a specific pattern of pulses.
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Transmitters
• The common signal ranges are as follows:
– 4-20 mA DC
– 0-20 mA DC
– 0-10 V DC
– 3-15 psi
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Transducers
• Most batch and continuous process control machines
have a large variety of instruments that do not respond
to the same types of signals.
• To enable these instruments to work together, some
type of signal conversion is necessary.
• Transmitters perform this function and also provide
long-distance transmission by using an amplifier.
• When long-distance transmission is not required,
another instrument called a transducer is sometimes
used to perform the signal conversion function.
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Transducers
• The most common transducers are:
–I/P and P/I transducer (Current /
Pneumatic)
–I/E transducer (Current / Voltage)
–D/A and D/A transducer (Digital /
Analog)
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I/P Transducers
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P/I Transducers
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I/E Transducers
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Other Transducers
• Some other types include
–Square root extractor
• Mainly used to linearize square nonlinearity
–Digital to analog transducer
–Analog to digital transducer
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Controller
• There are different types of controllers
–Pneumatic controllers
–Panel mounted controller
–Personal computers
–Programmable logic controllers
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Pneumatic Controller
–Pneumatic controllers produce a pneumatic output
signal that is applied to a flow control valve.
–They are usually located in the field and are mounted
near the point of measurement.
–These controllers are usually found in older systems
and are capable of controlling only one loop
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Panel Mounted Controller
–The panel-mounted controller is a microprocessor-based device
which can measure, display, and control temperature, pressure,
level, flow, and other process.
–This device is relatively inexpensive and is capable of performing
simple on-off as well as PID-type control operations.
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Personal computer Controller
–The personal computer (PC) can be used for small systems that are easy to
control.
–Software programs provide the control of on-off, PID, and multiple-loop
operations.
–Some types of software programs show the real-time operations on a graph
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PLC
–The programmable logic controller (PLC) can perform most
control operations for very complex systems.
–Discrete I/O-modules perform on-off batch operations.
–Input analog modules are capable of interfacing with sensors
and -transmitters, and output analog modules can send control
signals to final control elements used in a continuous process.
–The CRT used by the PLC can display information
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SCADA and DCS
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Monitoring instruments
• Various types of instruments are designed to
monitor the process control operation.
• They can be mounted on a control panel or on
the controller itself, or can be a dedicated
unit.
• These instruments include indicators, alarms,
and recorders.
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Monitoring instruments: Indicators
• Indicators are used to display information for
the operator or technician.
• They show data such as set point adjustments,
the amplitude and polarity of an error signal,
or the magnitude of the signal sent to the final
control element by the controller.
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Monitoring instruments: Alarms
1. deviation alarm: which activates when the controlled
variable differs from the set point by a certain value.
2. rate-of-change alarm: which turns on when a
controlled variable is increasing or decreasing at a faster
rate than desired.
3. limit alarm: which is initiated if the controlled variable
reaches or exceeds a predefined value. For example, the
alarm system will turn off a feed pump if the level in a
storage tank, to which it supplies a liquid, reaches a
certain height.
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Monitoring instruments: Alarms
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Monitoring instruments : Recorders
• In some types of manufacturing equipment, such as
paper machine, a large number of variables must be
continuously monitored and controlled.
• This information is often recorded to be read and
analyzed at a later date
• For example, suppose that some bad rolls of paper
are discovered by the quality control department. By
reading data charts that were recorded while the
paper was being made, it may reveal the issue/fault.
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Monitoring instruments : Recorders
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Monitoring instruments: Recorders
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Manipulation Devices
(Final Control Element)
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final control element
• In process control systems, the final control element is
the device which directly influences the process
variable.
• In a closed-loop system, it changes or maintains the
value of the process at the desired point.
• There are many types of final control elements, such as
pumps, motors, fans, compressors, heaters, dampers,
and so on.
• The most widely used final control element for process
control, however, is the control valve.
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The control valve
• The control valve is a mechanism that regulates the amount
of fluid flow by varying the size of the passage through which
fluid passes.
• The fluid can be a liquid, a gas, or a vapor.
• The control valve is made up of two distinct parts:
• The valve body, which becomes a part of the main process
line by being connected to the pipes through which the fluid
in the system passes.
• The valve actuator, which provides the force needed to
physically change the size of the flow passage inside the valve
body.
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Sliding-Stem Globe Valves
• The globe valve is the type most commonly
used for controlling the flow of fluids. It gets
its name from its globular-shaped cavity
located around the port region.
• Three different types of globe valves are:
–Single Seated
–Double Seated
–Three Way
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Sliding-Stem Globe Valves: Single Seated
• It consists of a single plug and seat.

• The fluid enters the port beneath the seat
and creates an upward force against the
valve stem that is pushing the plug
downward.
• As long as the pressure from the process
line does not exceed the force from the
valve stem, tight shut-off will occur.
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Sliding-Stem Globe Valves: Double Seated
• The double-seated valve, has two plugs and two

seats.
• It is designed so that the line pressure creates an
upward force on one plug, and a downward force
on the other plug.
• This configuration creates a balanced condition to
allow the valve to be used for applications
involving high pressure, fluctuating pressure, or
where the valve size is large.
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Sliding-Stem Globe Valves: Three way
• The three-way valve has three external

ports connected to three different pipes.
• It is used primarily for mixing.
• There are two inlet ports through which
different fluids enter.
• Inside the valve body, the liquids
converge and then exit the outlet port.
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Rotary Motion Valves
• There are two common types of
rotary valves, butterfly and ball.
• They get their names from the shape
of their restrictors.
• By rotating on a shaft, the restrictor
alters the flow by changing the area
through which the fluid passes
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Rotary Motion Valves: Butterfly
• The butterfly valve contains a vane or a disk restrictor
to provide the valve closure
• One advantage of the butterfly valve is that the valve
body around the restrictor is small.
• Also, since the fluid passes straight through the valve,
there is no accumulation of stock or sludge like there is
with globe valves that have pockets.
• Butterfly valves are used in applications where high
static pressures with small pressure drops across the
restrictor are desired.
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Rotary Motion Valves: Ball
• The ball valve contains a plug that is spherical in
shape and has either a notch or a circular port.
• When it is activated, the plug rotates up to 50
degrees.
• At zero degrees the port is completely open,
and at fifty degrees it is completely closed.
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• As the plug turns, it varies the flow from
minimum to maximum capacity.
• Ball valves have the greatest flow capacity of all
control valves.
• They have low maintenance requirements, and
they withstand corrosive materials very well.
• These valves are often used to control fibrous
flows such as pulp stock, paper stock, and
slurries.
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Selecting a control valve
• The result of a survey conducted in recent years has
revealed that improper control valves are used in
roughly one-third of all installations.
• When the wrong valve is used; plant efficiency and
product quality are degraded.
• When selecting the proper control valve for a particular
application, two factors must be considered: valve
capacity and valve characteristics (fast or slow
opening).
• Based on experience.
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Valve Capacity
• Valve capacity refers to the amount of material that a valve is
capable of allowing to pass.
• The size of the valve has an effect on the amount of system
pressure that is dropped across its inlet and outlet ports.
• The smaller the valve, the larger the pressure that is
developed.
• The amount of pressure differential needed for good control
is a function of the pressure dropped across the valve with
respect to the rest of the system.
• A rule accepted by many designers is that 50 percent of the
system pressure should be dropped across the valve.
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Valve Capacity
• A valve that is too small creates two
problems:
– The controller of the closed-loop system
will usually cause the valve to be fully open
because it is not passing enough fluid.
– Small movements in the valve restrictor
may cause a change in flow that is greater
than desired.
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Valve Capacity
• A valve that is too large (more common) also creates three problems:
– The controller of-the closed-loop system will cause the valve to always
operate at or near the closed position. The result is that the valve plug
may slam into or bounce out of the valve seat. Also, excessive seat
or valve wear may result from the high velocity flows between their
surfaces due to the small amount of passage area.
–The differential pressure across the valve (relative to the system
pressure) becomes small, resulting in sloppy and slow control
responses because large movements of the restrictor will cause
small changes in flow.
–Large valves are more expensive than smaller valves.
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Valve Characteristics
• The valve characteristic is the
relationship of the change in the
valve opening to the change of flow
through the valve.
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Valve Characteristics
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Valve actuator
• The mechanism that physically moves the
element which restricts flow in a control
valve is the actuator.
• Three types of valve actuators are
commonly used:
–Manual
– Pneumatic
– Electrical
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Valve actuator: Pneumatic
• There are two types of actuators, the spring-and-
diaphragm and the piston.
• Because of its dependability and simplicity of
design, the spring-and-diaphragm actuator most
frequently used
• How much the actuator moves the restrictor is
determined by the magnitude of a pneumatic
signal.
• The pneumnatic actuator is the most widely used.
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Valve actuator: Electrical
• Actuation using the electrical method is
performed two different ways.
• When performing the on-off control mode, a
solenoid is used to switch the valve.
• When current flows through the coil, a magnetic
field is generated, which moves the plunger
downward against the spring.
• When the current stops, the spring pulls the
plunger in the opposite direction. '
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• When performing the proportional control
mode, a small motor is used to move the valve
stem
• A DC control signal is applied to a gear motor to
move the valve stem upwards or downwards.
• A position sensor incorporated in the valve
stem feedbacks the valve stem position to the
controller.
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Instrumentation
symbology
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Instrumentation symbology
• In the field of electronics, schematic diagrams use
symbols and lines to show which components are
in a circuit, and how they are connected.
• Likewise, in the field of process control, drawings
called Piping and Instrumentation Diagrams, or
simply P&I diagrams or P&IDs,are used.
• P&IDs are a standard format used in all types of
process control fields, such as the petroleum,
food, or utility industries.
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Instrumentation symbology
• These drawings contain more information than just
symbols and lines.
• Circles, letters, lines, numbers, and symbols are used to
indicate which devices are included in a system, how
these devices are arranged, where they are -located,
and which function they perform in the process.
• A thorough understanding of these diagrams will help
the operator or technician monitor processes, do
routine work more efficiently, and save time
troubleshooting.
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A sample P&ID:
A typical heat exchanger
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General symbols
• To indicate an individual instrument in a process
control diagram, a circle called a balloon is used.
• The balloon contains letters, lines, and numbers that
identify its location and its function in the process,
and further specifies whether it is used to measure,
indicate, record, or control the process variable.
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General symbols
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General symbols
• A circle by itself indicates a discrete stand alone
instrument, such as a transmitter, sensor, or alarm.
• If the symbol is a circle in a square, the instrument is
described as a shared device, which means that, in
addition to performing a measuring function, it also
displays or controls the process variable.
• If a hexagon is used instead of a balloon, it indicates a
computer function.
• A programmable controller is identified by a diamond
inside a square.
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General symbols
• Some symbols are divided in half by a single or
double horizontal line, a dashed line, or are
without any lines.
• These lines, or absence of lines, indicate how
the instruments are mounted.
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General symbols
• A symbol without a horizontal line designates that it is
installed in the field near the point of measurement or
near the final control element.
• A-solid line indicates the instrument is board-mounted in
a control room and is easily accessible to the operator or
for routine maintenance.
• Symbols with a dashed line denote an instrument located
behind a panel, which may not be easily accessible.
• Double lines specify that the instrument is at an auxiliary
location, away from the process.
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Tag Numbers
• Since there may be many different instruments used in
a process, an alphanumeric code is placed inside each
symbol to identify it.
• These instrument identifiers are called tag numbers.
• The code provides a variety of useful information
about each instrument. Letters, called functional
identifiers, are located in the top portion of the
symbol.
• The sequence of letters designates the internal
function.
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Tag Numbers
• The first letter denotes the measured or the initializing
process variable. For example, P indicates pressure, T is
temperature, F represents flow, and L means level.
• The second letter tells the function of the instrument.
For example, I represents indicate, R is for record, C
indicates control, and T means transmit.
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Tag Numbers
• When there are three identifiers, the second letter
provides additional information about the first letter.
For example, if PDI is used, D means that the
pressure (P) is differential pressure.
• The I represents an indicator, which means that the
instrument displays differential pressure.
• An example of a four-letter identifier is PDAH, which
indicates that the instrument is a differential
pressure alarm which-is activated when the pressure
is-too high.
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Tag Numbers
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Tag Numbers
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Tag Numbers
• The -numbers located in the bottom portion of the
symbol are the loop identifiers.
• A loop consists of one or more instruments arranged
to measure and control a process variable.
• The loop ID identifies the loop where the instrument
is located.
• All of the instruments in one loop are given the
same loop number, regardless of the function or
location of the instrument.
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Tag Numbers
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Summary of General symbols and Tag
Numbers
In summary, the symbols, along with the letters and
numbers inside them, provide the following
information about the process system:
1. Identify the measured variable controlled by the
loop
2. Identity the function of the instrument
3. Show how the instrument is mounted
4. Identify the loop number of the location where
the operation is performed
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Line symbols
• The symbols in a P&ID are interconnected by
lines.
• Instead of using solid lines, such as those used
in an electronic schematic diagram, various
types of lines are used to represent the
specific nature of the signal and how the
instruments are connected to the process and
to each other.
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Line symbols
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Line symbols
• Solid Bold Line: The thick solid line shows the process piping
that contains the process material such as steam, raw
materials, or the final product.
• Solid Fine Line: The thinner solid lines indicate that an
instrument is connected directly to the process. For example,
the figure shows how a field mounted pressure orifice
transmitter is connected directly to the process within the pipe.
PT
401
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Line symbols
• Other types of line symbols on a P&ID drawing represent signal
lines that carry electrical, pneumatic, or optical information.
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Valve and Actuator Symbols
• In P&ID drawings pictorial symbols are used to
show valves and the actuators that position
them.
• Squares, triangles, and circles are used to
show the different types of valves, dampers,
and actuators that control the flow of fluids.
Dr. Ammar Hasan

Dr. Ammar Hasan

Dr. Ammar Hasan

• Angle Valves: Angle control valves are installed at a
point where there is a bend or turn in the piping.
Their inlet and outlet ports are at right angles to
each other. They are usually used in applications
where the piping layout does not permit the
installation of a globe valve.
• Dampers or Louvers are rotary action devices used
to vary the volumetric flow rate of gas or air. They
are typically used in heating, ventilation, and air
conditioning systems.
Dr. Ammar Hasan

• Valves are opened/closed by actuators that can be
automatic or manual.
• Most valves are activated by a pneumatic diaphragm.
• The figure shows a pneumatic diaphragm actuator
connected to a globe control valve.
• Notice that a fine line with two diagonal dash markings is
used to indicate a pneumatic input signal to the diaphragm.
Dr. Ammar Hasan

Reading a single loop
• The information provided on instrumentation
symbology so far is only a fraction of the
amount of information on the subject.
• An entire manual is needed to provide a
complete listing
• However, enough information has been given
to read simple drawings.
Dr. Ammar Hasan

Example 1: Heat exchanger
Dr. Ammar Hasan

• The tag numbers on the component symbols
indicate that the portion of the P&ID is loop
401.
• The first letter of each functional identifier. is a
T, which means that it is a temperature loop
Dr. Ammar Hasan

• The instrument connected to the heat
exchanger for measuring temperature is a
transmitter, which is labeled with a T as
the second letter of the functional
identifier.
• The balloon has no line inside its symbol,
which indicates that it is field mounted.
• The line with X’s indicates that a capillary
tube sends a signal from the exchanger to
the transmitter.
• A dashed line that extends from the
output of the transmitter indicates that it
produces an electrical signal.
Dr. Ammar Hasan

• The electrical signal from the
transmitter is sent to an instrument
that performs two functions,
indication and control: this function
is identified by the second and third
letters (IC) of the functional
identifier.
• The solid line inside the balloon
tells that it is board mounted.
• The controller sends out an
electrical positioning signal, as
indicated by the dashed line
extending from the left of the
symbol.
Dr. Ammar Hasan

• The flow control valve is actuated
pneumatically, therfore, a transducer is
required to convert the electrical signal from
the controller to a pneumatic signal.
• This function is performed by the I/P
transducer. The transducer function is
described by the second letter (Y) inside the
balloon.
• The I-to-P conversion is identified by the
small square, located in the diagonal position
to the balloon, containing the letters I/P.
• The fine solid line with diagonal markings
between the transducer and the actuator
shows that it is a pneumatic line.
Dr. Ammar Hasan
• The half circle symbol of the
actuator indicates that it
consists of a pneumatically
controlled diaphragm.
• The arrow that points
downward between the
actuator and globe valve
symbol tells that it is a “fail
closed” type of valve.
Dr. Ammar Hasan

Example 1: Heat exchanger
Dr. Ammar Hasan

Example 2:
Soda ash and Phosphoric acid reaction
Dr. Ammar Hasan

• In loop 101, soda ash flows into the mixing vat.
• The flow is detected by an orifice flow sensor, which
is shown connected directly to the process.
• It sends a pneumatic feedback signal to a flow
indicator/controller mounted behind the panel.
• FIC 101 sends a pneumatic signal to a diaphragm
which controls the valve that regulates flow.
Dr. Ammar Hasan

• In loop 102 an analyzer sensor that monitors

pH sends-an electrical signal to an indicator
/controller.
• An analyzer transducer converts the electrical
signal from the controller to pressure, which
causes a diaphragm to change the valve that
controls the flow of phosphoric acid.
Dr. Ammar Hasan

Ch15 - Industrial Process Techniques

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Ch15 - Industrial Process Techniques

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Chapter 15

Industrial Process Techniques and

Dr. Ammar Hasan

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Indicator Alarm Recorder

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