Process Control Instrumentation Polytechnic Books PDF Download
Process Control Instrumentation Polytechnic Books PDF Download
DIRECTORATE OF TECHNICAL
EDUCATION CHENNAI – 600 025
M – Scheme
e-TEXTBOOK
on
PROCESS CONTROL INSTRUMENTATION
for
V Semester DICE
Convener for ICE Discipline:
Dr.S.Rajakumari,
Head of Department/ECE,
Dr.Dharmambal Govt. Polytechnic College for Women,
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Tharamani, Chennai - 600 113
Dr.P.Parvathy M.E.,Ph.D.,
Lecturer (Sr.Gr.) / ICE,
280, ADJ Dharmambal Polytechnic college,
Nagapattinam – 611 001
Mrs.J.Bhuvaneswari B.E.,
Lecturer / ICE,
363 , Srinivasa Polytechnic College,
Kalamavur,
Pudukkottai- 622 502
Validated By:
Mrs. J.RAMA
REGIONAL OFFICIER 1V
Directorate of Technical Education
Guindy, Chennai – 600 02
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methods of tuning – open loop response method – process reaction curve – closed loop
response method – ultimate cycle method - damped oscillation method.
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REFERENCE WEBSITES:
http://en.wikipedia.org/wiki/PID_controller
http://en.wikipedia.org/wiki/Control_valves
VIDEO LECTURES:
http: //nptel.ac.in/courses
http: //www.youtube.com/watchv=vCCc2-qYS2A
http://freevideolectures.com/Course/3126/Process-Control-and-
Instrumentation http: //myopencourses.com/subject/process-control-and-
instrumentation-2 http://www.classiclearn.com/chemical-engineering/process-
control-and instrumentation-video_9569d1936.html
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Process – Continuous and Batch process – process variables Functional block diagram of
an automatic process control system – set point – measured value – error - simple liquid
level control system – flow control system – temperature control system with
transportation lag – self regulation – Introduction to Piping and Instrumentation
diagram-symbols for equipments, piping, instrumentation and control, P&ID diagram
for simple liquid level control system.
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1.1 Process
In process control, the word process refers to continuous processes.
Energy generation, electric power transmission and distribution systems, chemical
and petrochemical industries, paper and pulp processing industries, food industries
are examples for processes. A sequence of operations or actions is known as process.
These sequences of operations will give a result or end product. Temperature,
pressure, flow, and level are the important process variables. The performance of
the process is measured from the process variables. Process control instrumentation
improves quality control, efficiency, protection and safety. It removes isolated or
hazardous atmosphere. Non-linear process, non-availability of sensors for
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accurately measuring the variables, time delay, inter-related multi-variables in the
process, high sensitivity towards noise and disturbances are the difficulties in
implementing process control.
To maintain or regulate the process variables at a constant, desired
value is known as process control. From the given raw materials, a useful end
product is produced by a series of actions. In some process there are more than one
process variable. If only one variable is controlled in a process, then it is known as
single-variable process. If more than one variable is controlled in a process, then it is
known as multi-variable process. A process control system must:
1. Reduce outside load disturbances.
2. Increase the stability of process.
3. Optimize the performance of the process.
Process dynamics is the time response of the process when it is
disturbed by load disturbances.
1.3.1 Process
To produce an useful end product from the raw materials through a
sequence of operations is known as process. The performances of the processes are
determined by measuring some of the process variables (temperature, pressure,
fluid, level).
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1.3.2 Measuring element
The variable which we want to control is called controlled variable. In
order to control the variable, the present value of the variable is continuously
measured using the measuring element. If we measure directly the controlled
variable, then it is known as primary measurement. If the controlled variable cannot
be measured directly, then other process variables which are reliable and easily
measurable can be measured. Let c(t) be the controlled variable. In order to
maintain the controlled variable at a constant value c(t) is measured. Measuring
element must convert any physical quantity to be measured into electrical signal.
The measuring element also includes a signal conditioning circuit to manipulate the
measured electrical signal so that it is accepted by the next comparator stage.
1.3.3 Comparator
The comparator has two input signals
i) The measured controlled variable.
ii) Set point (the set point has same units as measured value).
1.3.4 Set point (desired value)
The value of the controlled variable required for the operator or for
the application is known as set point. The comparator compares the measured
variable with the set point and determines the difference in value as error.
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1.3.5 Controller
Error e(t) is the input to the controller. The controller has to
determine how far the measured variable is deviated from the set point. It tries to
keep the measured variable at the set point, so that error e(t) is zero. Controller
output is given to final control element. The final control element changes the
manipulated variable to keep the controlled variable at the set point.
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ii) Manipulated variable
iii) Disturbances
All the process variables are classified into two types. They are input
variables and output variables.
Input variables: An input variable shows how the environment affects the process.
Disturbances and manipulated variables are the input variables.
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1.4.1Controlled variable
The variable which we use to maintain or regulate at constant
value is known as controlled variable. Figure 1.4 shows the process variables in a
process control system.
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Set point: The desired/required value of the controlled variable is known as set-point.
1.4.3 Disturbances
Due to changes in atmospheric pressure, room temperature etc,
the quality and quantity of input variable changes, these variables are known as
disturbances.
1.4.4 Example
A continuously stirred tank heater is shown in Figure.1.5. The water
in the tank is heated by passing steam. The tank is continuously stirred to keep all the
points at the same temperature. The temperature of the inlet cold water to the tank is Ti
and its flow rate is Fi. The temperature of the steam passing through the tank to heat the
cold water is Tst and its flow rate is Fst. After heating, the hot water flow out of the tank
with the temperature To and with the flow rate Fo. Since the water in the tank is
continuously stirred the temperature of the water at the outlet To and the temperature
of the water in the tank T are same. The level of the tank is h.
In the above process, Fi, Ti, Fst, Tst are input variables. Fo, To are
output variables. Steam flow rate Fst is the manipulated variable. The process is to
maintain the temperature of the tank water T at a constant value. Thus, T is the
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v) Reduces manual error.
vi) Reduces human tension.
vii) Saves energy.
viii) Overall efficiency of the plant is increased.
1.6 Uses of automatic process control in industries
i) Automatic process control instrumentation is used in heat
treating, assembly operations of petroleum, chemical, steel,
power and food industries.
ii) Used in workflow, heat treating, assembly operations of
automobile parts, refrigerators, TV, radio, and electronic
equipments producing industries.
iii) Used in transport systems like aeroplanes, railways, free
missiles, ship etc.
iv) Used in electric power supply units like compressors, pumps,
prime movers for position, speed, and power control.
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Let Fi=inlet volumetric flowrate (m3/s)
Fo=output volumetric flow rate (m3/s)
A=cross-sectional area (m2)
R=resistance to outlet flow caused by pipe, valve or weir,
etc h=liquid head in the tank
If liquid level h in the tank is high, then outlet flow rate Fo is also high.
Outlet flow rate Fo depends on level h of the tank. If outlet flow rate is resisted by a
valve, it is denoted by R. The flow rate also reduces due to friction of water particles
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The storage capacity of the tank depends upon the area of the tank.
Thus, time constant is the product of storage capacitance and resistance.
T=storage capacitance × resistance.
Level is measured using capacitance level transducer, bubbler
tube, and/or displacer tube. The level of the tank h is the controlled variable. By
changing the inlet flow Fi, the level is maintained at constant value. Inlet flow Fi is
the manipulated variable. The level in the tank is transmitted by a level transmitter
to the level controller. Based on the error, the controller opens or closes the control
valve and maintains the level at the set point. In industries, the tanks bottom and top
pressure values are connected to a differential pressure transmitter to measure the
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level.
Where,
Q=Volumetric flow rate (m3/sec)
Cd=Flow co-efficient
A=Area of cross section
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Ta, Qs, To, Ts are load variables. If the uncontrolled variables changes
individually, then the controlled variables will deviate from the set point.
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1.9.2 Dead Time
The time taken in between error and the corrective action.
1.9.3Transportation lag
In figure 1.11, the liquid in the pipe near the steam flow will heat
up immediately but the liquid at a distance from a pipe will heat up less because the
liquid near the pipe must heat first and the liquid particles propagate the heat to the
next point, it will take some seconds. This is known as transportation lag. The above
time interval is known as dead time, transportation, pure delay or distance velocity
lag. For better controller performance the system’s dead time must be well known.
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some processes even though the load is nominal without any control operations. The
controlled variable is constant at some specific value. This is known as self regulation.
Figure 1.9 has self regulation. The steam valve position is kept at 50% and the control
loop is opened, so that the controller is disconnected. Steam in the tank will heat upto a
point where input energy from steam flow and the liquid’s energy are equal. If the load
changes, it will attain a new temperature because the systems temperature is not
controlled. In this condition, the process has self regulation. It will stabilize next
temperature value.
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TABLE 1.1 Letter code
FIRST LETTER SUCCEEDING LETTERS
PROCESS MODIFIER READOUT OUTPUT MODIFIER
VARIABLE
A. analysis A alarm
B. burner * * *
C. conductivity C controller
D. density D differential
E. voltage primary
element
F. flow F ratio
G. gauging G glass
H. hand high
I. current I indicator
J. power J scan
K. time K control
station
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instrumentation drawing or P and ID. The symbols used are standards that have been
developed through the years and are accepted by the Instrument Society of America.
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of the process itself. We use the symbol of a line to denote the nature of the signal.
Figure1.14 Piping and Connection symbols
These symbols are used to identify how the instruments in the process connect to each
other and the type of signal used.
Figure 1.6 shows the P and ID diagram for simple liquid level control system
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Figure 1.16 Instrument symbols
REVIEW QUESTIONS:
Part A
1. Define a process.
2. Define set-point.
3. Define measured variable.
4. What is comparator.
5. Define controlled variable.
6. Define manipulated variable.
7. Write any two advantages of automatic process control system.
8. Draw the functional block diagram of an automatic control system.
9. Define capacity & capacitance.
10. What is final control element.
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1. Draw the P&ID drawing for simple liquid level control system.
2. Write short notes on transportation lag.
3. Write short notes on self regulation.
4. Write short notes on capacity and capacitance.
5. Write short notes on measured variable, controlled variable and
manipulated variable.
Part C
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Figure 2.1 Block diagram of a Controller
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The other case, if the controller is used to control the outlet valve, it is
direct acting. The valve is normally closed. If the level is increased above the set point,
the direct acting controller gives an output to open the outlet valve when the controlled
variable level increases, the controller output also increases to 100%. This is direct
acting controller.
2.3 Controller modes
2.3.1 Mode of control
The method by which the automatic controller produces the counteraction
is called the mode of control or control action. Controller is the most important part of
the process control loop. Based on the deviation between desired set value and actual
measured value the controller generates a control signal and gives it to the final control
element. The input to the controller is the error e(t) which is a measured indication of
how much the controlled variable c(t) has deviated from the set point r(t). The output of
the controller is a signal representing the action to be taken to reduce the error.
Normally controller is some form of computer analog or digital, pneumatic or electronic
which using the input measurement solves certain equations to calculate proper output.
Inputs to the controller are measured indications of both the controlled variable and a
set point representing the desired value of the variable expressed in the same fashion as
the measurement. The controller output is the signal representing action to be taken
when the measured value of the controlled variable deviates from the set point. The
measured indication of a variable is denoted by b, while the actual variable denoted by c.
If a RTD (temperature sensor) is used to measure temperature. Then the
actual variable is temperature in ⁰C but the measured indication is in resistance (ohms).
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where,
e=error
b=measured indication of variable
r=set point variable or reference
In this equation error is expressed in units of the measured analog
value of the control signal. To express error as percent of span
where
=maximum of measured value.
=minimum of measured value.
= error expressed as percent of span.
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Where,
p = controller output as percentage of full scale.
u = value of the output.
=maximum value of controlling parameter.
=minimum value of controlling parameter.
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Example: In domestic water heaters if the temperature drops below the
set point the heater is turned on, if the temperature is above the set point the heater
turned off. If error is positive, heater is on. If error is negative, heater is off.
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i) Process response is low.
ii) Load changes are low and small.
iii) There is no transfer lag.
iv) There is little or no dead time.
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2.4.3 Applications
Two position control modes are best suited for large scale systems with
relatively slow process rates. It is used in room heaters, water heaters, refrigerator, and
level control of water tanks, air conditioners, temperature and level control of large
volume tanks.
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where
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Kp= proportional gain between error and controller output (%per%).
P= controller output (%).
ep=error (%)
P0= controller output with no error (%).
The adjustable parameter of the proportional mode Kp is called the
proportional gain or proportional sensitivity. Each value of the error has unique value
of controller output. There will be a one-to-one correspondence. The range of error to
cover 0%-100% controller output is called the proportional band (PB) because the one-
to-one correspondence exists only for error in this range.
The proportional band is equal to the inverse of the proportional gain.
The proportional band is defined as the range of error over which it must
change in order to drive the actuating signal of the controller over its full range. A graph
of the proportional mode output versus error is shown in figure 2.9. The proportional
band depends on the gain. High gain means large response to error. The characteristics
of proportional control mode are as follows:
1. If the error is 0, the output is a constant value equal to p(0).
2. If there is error, for every 1% of error a correction Kp% is added
to or subtracted from p(0) depending on the reverse or the
direct action of the controller.
3. There is a band of error about 0 of the magnitude PB within which
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2.6.2 Offset
Whenever a change in load occurs, the proportional control mode
produces a permanent residual error in the operating point of the controlled variable
which is known as “offset”. Offset can be minimized by large, constant Kp which also
reduces the proportional band. Proportional control is used in processes with moderate
to small process lag times.
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Figure 2.10 Proportional action with provision for changing
PB Pivot at centre:
If the input changes to 100%, then the output changes to 100% (PB=100%).
Pivot to right:
If the input changes to 100%, then the output changes to 50% only. To get
100% change in output, the input must be changed to 200%.
Pivot to left:
If input change is 50%, then the output change is 100% (PB =50%).
The range of error required to move the controller output from 0% to
100%is known as proportional band.
(%)
where,
Kp=proportional gain,
PB=proportional band.
These two are inversely proportional to each other. If proportional gain KP
increases, proportional band PB decreases. If proportional gain reduces, proportional
band increases (sensitivity is less). If the value of Kp is very high, PB is very less. Then,
proportional controller will act as on-off controller.
The steady state response of a proportional controller will have
permanent steady state error. This error is known as offset.
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Figure 2.11 Proportional control exhibiting offset
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Where,
=rate of controller output change (% per sec)
=constant relating the rate to the error (% per sec/%)
The integral time expressed in seconds or minutes. is defined as
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Where,
= derivative gain constant (%-s/%)
=rate of change of error (%/s)
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Figure 2.16 Response of derivative control mode to terminated ramp input
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Where,
=integral term value at t=0.
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change of deviation e, the integral time or reset time is the time required to add an
increment of response equal to the original step change of the proportional action as
shown in figure 2.17. Reset rate is defined as the number of times per minute that the
proportional part of the response is duplicated. Reset rate is called repeats per minute
and is the inverse of integral term .
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Applications:
PI mode can be used in systems with frequent or large load changes.
Disadvantages:
The process must have slow changes in load to prevent from
oscillations induced by the integral overshoot. During start-up of a batch process, the
integral action causes an overshoot of the error. When error cannot be eliminated
quickly and given enough time. This mode produces larger and larger values for integral
time which in term keeps increasing the control action until it is saturated; this condition
is called integral windup. This occurs during change over operations and shutdowns.
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This mode eliminates the offset of the proportional mode but still
provides fast response. The three adjustment parameters are proportional gain,
integral time and derivative time. PID controller can give better control than 1 or 2
mode controllers. In practice, it’s difficult to select the tuning parameters for PID
controller. The derivative mode in PID controller is used to compensate for
hardware lacks in the process. PID controllers are used in the industries to control
slow variables such as temperature, pH and analytical variables. The figure 2.20
shows transient response of continuous controllers for step input.
The input signal (a step change).
Output variable (manipulated variable).
Proportional control action:
Final control element is operated by an amount proportional to the
deviation.
Proportional+reset action controller:
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For a) and c) processes P+D mode is used. For
a),b),c) processes P+I+D mode is selected.
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Where,
=controller output (0-100%),
=Proportional gain
=error in %
= controller output when error is 0.
If we change the controller output and error as voltage, the equation
becomes
= error voltage.
Input error signal of Op Amp is scaled for full range of error signal.
Output signal is scaled for 0-100% or 4-20mA controller signal. Proportional gain is
adjusted using
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Figure 2.25 Circuit diagram of an electronic integral controller
where,
; integration constant.
=error voltage,
=initial output voltage.
The output of integrator in the first stage is , if we change the
value of R and C, we can get required integration time. Integration time constant
indicates the ratio of increase in controller output when error is constant. If the value of
is very large, output will increase above setpoint and results in overshoot. The
output response will have cycling / oscillations.
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where,
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=Error in percentage
P=Controller output
P0=Controller output when error is 0
=Derivative time constant (s) ( =R2C).
In electronic derivative controllers, the input error and controller output
are mentioned in voltages. The equation for electronic derivative controller is
Where,
=error voltage,
=output voltage when error is 0.
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integration gain, the value of is modified. The figure 2.27 shows the circuit of
PI controller.
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The figure2.28 shows the circuit of Electronic PD controller.
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; ; and =
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Figure 2.31 Electrical equivalent of basic flapper nozzle system
Figure 2.32 Curve relating the nozzle back pressure and nozzle flapper distance
Pressurized air PS is supplied through an Orifice. The velocity of out coming air
is high. This high velocity air is moved towards the flapper. Flapper is designed to close the
nozzle’s hole. So, the air cannot pass through the nozzle and results as back
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ball can able to move up and down. If the ball is in its upper seat, it blocks the air to
atmosphere. All the supplied air PS will come out as output pressure P. If the ball is at its
lower seat, the supply air PS is blocked. The output pressure PS is reduced to atmospheric
pressure. Thus, the output pressure P can be varied from atmospheric pressure to
supply pressure. If the flapper moves away from the nozzle, back pressure Pb will be less,
bellow will contract, the ball connected to the bellow will move up to the upper seat.
This action closes atmospheric hole, the output pressure will increase. If the flapper
moves towards the nozzle-back pressure increases, the bellow starts expanding, the ball
connected to the bellow closes the output pressure path. So, the output pressure reduces
towards atmospheric pressure. The pneumatic relay boosts up the output pressure of
the flapper nozzle. All the time except the ball at its upper seat, the air will bleed from
the pneumatic relay. So, it is known as bleed relay. The basic component of pneumatic
system is flapper-nozzle. In order to amplify the output pressure, pneumatic relays are
used along with flapper and nozzle. Pneumatic systems are safe and give less power. Air
leakage is common, has high operating temperature range.
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1.
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REVIEW QUESTIONS
What is controller?
PART A
(2)
2. What are the types of controllers?
3. What do you mean by controller mode?
4. Define proportional band.
5. Define proportional gain.
6. What is integral time?
7. Define differential time.
8. What is called an offset in proportional controller?
PART B
1. Define reverse and direct actions of the controller. (3)
2. Define self regulation.
3. What is offset? How is it eliminated?
4. Differentiate between discontinuous and continuous controller modes.
5. When on-off controller is suitable?
6. Give applications of on-off control.
7. What are the different control modes in process control?
8. What is proportional mode?
9. Give the controller equation of proportional mode.
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Concept of tuning – criteria for controller tuning – quarter Decay ratio, IAE, ISE, ITAE –
methods of tuning – open loop response method – process reaction curve – closed loop
response method – ultimate cycle method - damped oscillation method.
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3. TUNING :
After Selecting the type of feedback controller , one has to decide values for
its adjusted parameters like KP, KI, KD . This Process of deciding values for adjusted
parameters ( Tuning Parameters ) is called Tuning.
The Tuning of process control loop consists of finding the optimum settings
of controller gains for good control.
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1. Using simple criteria such as the one – quarter decay ratio ( ¼ decay ratio
) minimum settling time , minimum largest error and so on.
2. Using time integral performance criteria such as ISE,IAE or ITAE.
3. Using semi empirical rules which have been proven in practice.
There are many methods for determination of the optimum mode gains,
depending on the nature and complexity of the process. Here three common tuning
methods are considered to give a basic idea of how optimum adjustments are found.
The Decay Ratio is the ratio of the amounts above the ultimate value of two
successive Peaks. If the ratio C/A is equal to ¼ then the ratio is quarter
Decay Ratio.
Decay Ratio ,
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ISE =
IAE =
Where ITAE =
The types of the controller and the values of its adjusted parameters may
be selected in such a way as to minimize the ISE,IAE, or ITAE of the system’s Response.
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1. Different criteria lead to different controller designs.
2. For the same time Integral criterion , different input changes lead to different designs.
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1. The Control loop is opened by disconnecting the controller from the final control
Element.
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Variable using the final control Element.
The open loop controller response , where the input change ( disturbance) is
applied at t1.Controlled variable and error are taken in the y – axis and expressed in %.
A Tangent line is drawn at the inflection point of the curve. The inflection point is
defined as that point on the curve where the slops stops increasing and begins to
decrease.
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From t2 to t3 , we get T , the process reaction time. The reaction rate N is given by
N=
Where,
R=
Where ,
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Proportional Mode :
For the proportional mode , the proportional gain setting Kp is found from
Kp =
The appropriate settings for proportional gain and integration time are
Kp =
Ti = = 3.33L
Kp =
Ti = 2L
TD = 0.5 L
This method can be used only for systems with self regulation .
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2. Gradually begin to increase the proportional gain while providing periodic small
disturbances to the process.
3. Note the critical gain , Kc, at which the dynamic variable just begins to
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exhibit steady cycling ( Oscillations about the set point )
Proportional Mode :
Kp = 0.5Kc
Kp = 0.45 Kc
TI =
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PID Mode :
KP = 0.6 KC
TI =
TD =
TI =
TD =
And the proportional gain is adjusted for the quarter – amplitude response.
1.
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In this method , proportional gain is only adjusted , until a response
curve with a decay ratio ¼ is obtained.
Ti =
Td =
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REVIEW QUESTION :
PART – A ( 2 marks )
1. Expand ITAE.
2. Mention the closed loop response method of controller tuning used in
process control.
3. What are the tuning Criteria.
4. Write down the methods of controller Tuning.
5. What is the Expansion of IAE.
6. Name any one method of closed loop tuning of controller.
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4 . INTRODUCTION :
Final control Elements involve in the steps necessary to convert signal into
proportional action on the itself. The final control elements is the mechanism , which
translate the signal from manipulated variable to the process variable . The position of
the final control element is shown in the figure.
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The previous Stage of the final control element is controller. Different types of
controller are used in process control Pneumatic , Electronic , Hydraulic Set. If the output
of the electronic controller is given to the final control element. The final control element
use in the process is Pneumatic one.
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P to I
( 4 – 20 ) mA
CONVERTER
3-15 psi
CONSTRUCTION :
The output of the Bellows is connected to the LVDT shaft. The LVDT takes the
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input as Linear Displacement and it gives the output as voltage. The output of the LVDT
is given to the voltage to current converter.
OPERATION :
The Pressure Signal ( 3 – 15 psi ) is given to the Bellows, the Bellows converts the
Pressure Signal into Linear Displacement. The output of the Bellows is given to the
LVDT. The Displacement is given to the LVDT Shaft.
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The voltage to current converts the voltage into corresponding current value.
This current value is proportional to the Manipulated Variable.
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Fig 4.5 I to P Converter
As the flapper moves away, the signal pressure will drop because of the leaking
gas. Finally , when the flapper is far away , the pressure will stabilize at some value
determined by the maximum leak through the nozzle.
When 4 mA is applied to the coil , the flapper will be far away from nozzle ,
maximum air leakage through the nozzle opening and the pressure will stabilize at 3 psi.
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The signal pressure will rise to 15 psi with minimum leakage of 5 psi. The flapper
nozzle system is most commonly used as current to pressure converter. I to P converter
translates the 4 to 20 mA current into 3 to 15 psig signal.
4.3 ACTUATORS :
The Actuator must provide an accurate output position proportional to the input
signal in spite of various forces acting on the output member. The most important forces
are
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4. A combination of these means.
4.3.1 PNEUMATIC ACTUATOR :
Pneumatic actuators may operate directly from the pneumatic output signal from
a pneumatic controller, or they may employ a separate source of compressed air. There
are five common methods of operation of pneumatic actuators. These are called
i. Spring Actuator
ii. Spring actuator with positioner
iii. Spring less actuator
iv. Piston actuator
v. Motor actuator
I) SPRING ACTUATOR :
A spring actuator operates directly from the air pressure output of a pneumatic
controller in order to provide an output position proportional to the input air pressure.s
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The diaphragm is usually made of fabric – base rubber , molded to form , and
supported by backing plate. The input air pressure m1 acts against the diaphragm and
causes a downward force which compresses the spring. At static balance , the force of
the air pressure against the diaphragm equals the spring compression force.
( m1 – m0 ) A = Kx
Where,
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m0 – input air pressure at zero stroke , lb / in2.
The standard input operating range of spring actuator is 3 to 15 psi gauge. The
output displacement or stroke is generally between ¼ and 3 in. And is limited by the
allowable stroke of the diaphragm. For longer strokes a piston – spring combination is
employed.
fn =
where,
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Static friction forces must be limited to a low enough value that excessive
hysteresis does not result. For hysteresis less than one percent of full travel,
Ff
Where ,
This may be a serious limitation. For example , a spring actuator with an effective
area of 100 sq in . And an operating range of 3 to 15 psi cannot support more than l2 lb
friction if the hysteresis is to remain less than one per cent of full range. Thrust forces are
also limited by the ability of the actuator to provide full operating stroke.
Ft
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Where Ft is the total thrust force acting in one direction. This may also be a serious
limitation. For Example, a spring actuator with an effective area of 100 sq in . and an initial
air pressure setting of 3 psi cannot support more than 300 lb unbalanced force.
In addition, thrust forces must be relatively constant otherwise the stem position
will not be directly related to the input air pressure. The performance of a spring
actuator is also influenced by the characteristics of the spring and diaphragm.
A well – designed actuator has a linear static relation between input air pressure
and output stroke if the effective area of the diaphragm and the spring gradient are
constant throughout the stroke. Hysteresis due to the stresses in the spring and
diaphragm are usually less than one or two per cent of full stroke.
The spring actuator often requires a positioner as shown in fig.4.7 When static
friction forces are large or when the response of the motor is too slow. The positioner
consists of an input Bellows , a nozzle and amplifying pilot, and the feed back levers and
spring . An air supply from 20 to 100 psig must be provided.
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The operation is as follows , when the input air pressure m1 increases , the input
bellows moves to the right and causes the baffle to cover the nozzle.
The nozzle back- pressure change is amplified by the pilot and is transmitted to
the diaphragm. The diaphragm moves down and the feedback lever compresses the
spring to return the baffle to a balanced position. Thus the actuator stem assumes a
position dictated by the input air pressure. The spring actuator becomes a power means
and the characteristics of the spring and diaphragm are relatively less important. The
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use of the positioner results in several improvements in performance.
2. The actuator can handle much higher static friction forces because of the
amplifying pilot.
The use of a positioner with a spring actuator does not improve the ability of the
actuator to handle larger inertia or thrust forces unless special adjustments of motor
operating range are made. The only disadvantages in the use of a positioner is that it
may require maintenance.
The spring less actuator is useful for large thrust forces. The only difference
between the spring less actuator and the spring actuator with positioner ,is that the
spring of the actuator is replaced by a pressure regulator which maintains a constant
pressure on.
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Then if the input pressure increases, the nozzle back pressure increases, and the
upper side pressure is raised to a high value. The actuator stem then moves downward
and , as the actuator stem attains the new position , the upper side pressure is returned
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to 9 psig. If there is an upward thrust force on the actuator stem, the underside pressure
remains at 9 psig but the positioner raises the upper side pressure until static balance is
achieved.
For a downward thrust force the upper side pressure is reduced below 9 psig.
Thus , the spring less actuator can counteract a thrust force equal to approximately the
underside pressure times the area of the diaphragm. This is generally from three to ten
times the thrust force handled by a spring actuator with or without a positioner.
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This action opens the upper side of the cylinder to the air supply and opens the
lower side to atmosphere , thus the action is to return the piston to the neutral position.
Thus the position of the piston is proportional to the input pressure. A double-acting
piston actuator can handle a thrust force equal to about 80 percent of the supply
pressure times the area of the piston.
V) MOTOR ACTUATOR :
The motor actuator is used for very large thrust force or torque. The air motor is a
reversible vane-type or positive – displacement type motor operating from 80 to 100 psig
air pressure .The operation is as follows , when the input pressure m1 increases , the pilot
piston moves upward and supplies high pressure to one side of these air motor.
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Fig 4.10 Piston Actuator
The other side of the air motor is exhausted. The motor drives the rack downward
, compresses the feedback spring and return the pilot piston to the neutral position.
Actuators of this kind are employed in sizes from 1 to 15 hp and will handle thrusts as
high as 100,100 lb.
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The input electric signal ( usually a direct current ) enters the ‘ voice – coil ‘
motor. The input coil is supported in the field of a permanent magnet so that the coil
affords a force proportional to the magnitude of the input dc current.
The force causes a deflection of the balance beam, covers the nozzle, and results
in an increase of output pressure. The output pressure acts on the feedback bellows to
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cause a torque on the balance beam equal but opposite to that of the voice coil. The
output pressure therefore is proportional to the input DC current.
The electro Pneumatic comparator combines the voice coil and the pilot in the
positioner of a pneumatic comparator. The motion of the output of the actuator is related
to the balance beam through the feedback lever. The output position of the actuator is
therefore proportional to input DC current.
Hydraulic actuator , as used for industrial process control , accept a signal from a
pneumatic controller or an electric controller and employ hydraulic pressure to drive an
output member. The hydraulic actuator is used where high speed and larger forces ( or
large power ) are required.
The hydraulic piston actuator has as its input m1, the position of the vertical lever.
For a pneumatic – hydraulic actuator the input would be the position of a bellows.
The balance lever pivots at the bottom so that an increase of input ( to the left )
pushes the pilot piston to the left. This action opens the left end of the piston to supply
pressure and opens the right end of the piston to drain
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The large power piston, therefore , moves to the right until, as the balance lever
rotates about the top most end, the pilot piston is returned to center , the motion of the
output x1 , is therefore proportional to the input motion m1. The hydraulic actuator
requires a continuously running electric motor and pump to provide a source of
pressure oil, and a drain or sump to collect the return.
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The input devices is the voice- coil motor which position a three – land pilot spool.
The pilot control the flow of oil to the cylinder, and the piston actuates the spring feed
back to the pilot spool. The operation follows: An increase in current to the voice coil
causes the arm to swing downward thereby pushing down the pilot spool.
This action connects the lower side of the cylinder to drain and connects the
upper side to supply pressure. The piston then moves downward , and the feed back
spring pushes back to rebalance the system in equilibrium. The position of the piston rod
is therefore proportional to input direct current.
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4.4 CONTROL VALVES:
Control valve is a variable restriction in a pipe line. Two operating principles for
automatic control valves are,
1. A fluid throttling control valve cannot operate with minimum differential head.
It regulates flow rate in a process control system. It is one of the final control
elements, which regulate level of energy of a process. They are widely used in variety of
industries including chemical, Fertilizers, Paper and Pulp, Petro chemicals,
Pharmaceuticals etc.
Construction:
Materials for valve body are used in accordance with performance of requirement
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of Pressure, Temperature and Corrosion etc.
Commonly used materials are iron, cast steel, stainless steel and Bronze.
The valve plug is screwed into stem and then pinned. It can be a single seated plug
which is guided at the top and bottom.
According to their basic shape plugs can be classified as Disc, V – Shape, and
contoured plugs.
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i) Butterfly Valves
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ii) Rotating Plug Valves
iii) Lifting Gate Valves
e) Rotating Shaft type Valves:
i) Butterfly Valves
ii) Rotating Plug Valves
iii) Lowers
f) Direct acting (or) Reverse acting Valve
4.5.1 VALVE CHARACTERISTICS:
By shaping plug and seat various valve characteristics can be obtained. Valve
Characteristics as shown in fig.4.14
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A quick opening valve plug produces a large increases in flow for a small initial
change in stem travel. Near maximum flow is reached at a relatively low percentage of
maximum stem lift. Quick opening plugs are normally utilized in two position “ON-OFF ”
applications but may be used in some linear valve applications. This is possible because
of its initial linear characteristics at a low percentage of stem travel. The slope of this
linear region is very steep which produces a higher initial gain than the linear plug but
also increases the potential instability of the control valve.
ii) LINEAR :
This characteristic provides a linear relationship between the valve position and the
flow rate. The flow through a linear valve varies directly with the position of the valve stem.
The flow-travel relationship, if plotted on rectilinear coordinates, approximates a
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These valves are often used for liquid level control and certain flow control
operations requiring constant gain.
The equal percentage valve plug produces the same percentage change in flow
per fixed increment of valve stroke at any location on its characteristics curve. For
example, if 30% stem lift produces 5gpm and a lift increase of 10% to 40% produces
8gpm or a 60% increase over the previous 5gpm, then a further stroke of 10% now
produces a 60% increase over the previous 8gpm for a total flow of 12.8gpm.
These types of valves are commonly used for pressure control applications and
are most suitable for applications where a high variation in pressure drop is expected.
The Pneumatic output from controller is sensed by a Diaphragm. The force on the
diaphragm is balanced by a force due to control spring.
The valve stems moves up or down as the input signal changes. It contains the
throttling mechanism, which consists of a plug attached to a valve stem and the valve
seat which is built in to the body.
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The valve stem displacement is limited by allowable stroke by the diaphragm. The
vertical movement of the plug and stem of the control valve changes the area of opening
of the port. The flow rate of the fluid passing through the port is therefore proportioned
or throttled by positioning the valve stem.
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m= K1a
where,
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Coil has a voltage and current rating. It can be excited by AC or DC voltage. Direct
The electric solenoid is widely employed for two position control with either or
alternating current. Spring – closing of Spring- opening types may be selected depending
upon which is desired for safe operation.
It specification also include push force of pull, when excited at a specific voltage .
Solenoid coil may be rated for continuous operation or intermitted operation.
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5. It is un affected by vibration.
4.5.3 SLIDING STEM CONTROL VALVE (OR) SPLIT RANGE CONTROL VALVE:
Control valves in which the plug is operated by means of reciprocating motion are
termed sliding-stem valves and are of the following types:
3. Lifting-gate valves.
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The single -seat plug valve has only one port opening between seat and plug and
the entire flow passes through this port.
1. It is simple in construction.
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The double-seat plug valve has two port openings and two seats and two plugs.
The port openings are not usually identical in size.
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Types of Plugs:
A few types of plugs for single seat and double seat valves are shown in fig.4.19
The piston type plug has one or more grooves along its length and the flow passes
vertically in the grooves between the plug and seat ring.
The V-Port type is open on the inside and the flow passes horizontally through
the triangular shaped area over the seat ring.
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Fig 4.20 Two types of double seat valve plugs
The parabolic plug presents an annular area to flow between the plug and seat
ring. The poppet-type plug offers a cylindrical – shaped flow area and is used with small
total lift.
The gate valve is often used for fluids containing solid matter, because it
presents an open are directly to the flow of fluid and does not involve a change of
direction of flow stream.
A gate valve can usually be shut-off tightly by wedging into the seat. The
chopping action at shut-off is very useful for stringy materials such as paper pulp.
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2. Butterfly valves
3. Louvers
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1. ROTATING -PLUG VALVES:
The rotating-plug valve is illustrated in fig.4.22 The plug is a cylindrical or
conical element with a transverse opening. It is rotated in the valve body by an external
lever so that the opening on one side of the plug is gradually covered or uncovered. The
shape of the opening or port may be circular , V – Shape , rectangular, or any form that
is desired to produce a given flow-angle characteristics
A rotating plug valve having a conical plug can generally be closed tightly and
has high range ability. This type of valve is often employed for throttling the flow of oil
to burner systems.
2. BUTTERFLY VALVES:
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The butterfly valves is consists of a single vane rotating inside a circular or
rectangular pipe or casing.
The shaft projects through the casing and may be operated externally. The total
rotation of the vane is usually restricted to about 60 degrees, because the additional 30
degrees does not produce much further increase in flow.
The V-port butterfly valve incorporates a V-slot in the body so that rotation of
the vane opens a portion of the V-slot. The flow-angle characteristics is shown in fig for
a 60 degrees butterfly valve.
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The range ability may vary from 5 to 50 and tight shut-off may be obtained with
special design. The butterfly valve is most often employed in sizes from 4 to 60 in. for the
control of air and gas. It is also used for liquid flow if the pressure differential is not large.
3. LOUVERS:
It consists of two or more rectangular vanes mounted on shafts one above the
other and interconnected so as to rotate together. The vanes are operated by an
external lever. In the uni rotational louver the vanes remain parallel at all positions.
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Fig 4.24 Louvers
A louver cannot provide tight shut-off because of the long length of seating
surfaces. Louvers are used exclusively for control of air flow ( draft ) at low pressure.
2. Range ability
3. Turn down
Q=K
Where,
K = Proportionality constant
Pressure difference
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It is defined as the flow of water in gallons per minute for a pressure drop of 1
psi across wide open valve.
Q = CV
Where ,
Typical value of CV for different valve size are indicated in the following table.
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¼
½
0.3
3.0
3
4
108
174
1 14.0 6 400
4.6.2 RANGEABILITY:
R=
Where ,
R = Rangeability number.
4.6.3 TURNDOWN:
T=
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The minimum controllable flow of control valve depends upon its construction ,
clearances must be allowed in order to prevent binding and sticking and the flow
through these clearances constitutes the minimum controllable flow.
The minimum controllable flow for a single seat valve is not zero unless the
throttling seat and shut-off seat are identical and have perfect alignment. The
rangeability of a sliding stem control valve is usually between 20 and 70.
b) The value of flow rate that will be required most of the time. This is the
normal flow rate.
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c) The minimum value of flow rate required to sustain the controlled
variable under any conditions or process operation. This is the normal minimum flow
rate.
2. Select the maximum flow rate which the control valve is to provide. This is
generally based on the normal maximum flow rate of about 70 percent of maximum
flow rate. The additional flow is a factor of safety which allows for low estimation of
pressure losses and high estimation of valve flow rate. The maximum flow rate usually
selected is about 1.4 times the normal maximum flow.
3. Select the style and type of control valve to provide best operation for the fluid
to be handled. Check the rangeability to insure that the minimum controllable flow is
generously smaller than the normal minimum flow rate desired.
4. Calculate the pressure differential at the control valve at the maximum flow.
This requires calculating line pressure losses, flow equipment pressure losses, and
determining upstream head from pump or fan characteristic curves.
5. Determine the control valve size from manufactures charts, or slide- rules. If
the fluid viscosity is high, or line velocities are exceptionally low ( Reynolds number in
the pipe line less than about 10,000 ) the size coefficient Cv will be low, and the
manufacturer should be asked to determine the valve size.
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The flow coefficient ‘ K ‘ and port area ‘ a ‘ are different for every style or size of
control valve.
10. Fluid characteristics such as viscosity, Density, specific gravity are also
considered.
Under normal conditions, fluid passing through a valve will undergo a pressure
drop across the valve orifice. The point of lowest pressure is called “ Vena contracta”.
The figure 4.25 shows the pressure drop and recovery in the pipe line.
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P1 is the fluid pressure at the inlet and P2 is the exit pressure and PV is the vapor
pressure of the fluid.
When the fluid passes the valve there is a pressure drop and fluid pressure
partially recovers and line pressure is again increased. The difference in pressure is
P1 – P2
The cavitations and flashing are undesirable phenomenon and hence it should be
avoided.
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It occurs in a valve when the pressure drop across the orifice result in pressure
less than liquid vapor pressure and then recover to above the vapor pressure. The
pressure recovery causes an implosion, or collapse of the vapor formed at the vena
contracta.
EFFECTS:
The cavity collapse produces shock waves and liquid microject. These impacts on
the adjacent surface of valves, pipes, and erosion damage can occur which reduces wall
thickness. Cavitations produces high level of noise and vibration. Excessive vibration
can loose, damage piping support, structure, and process equipment.
PREVENTATION:
FLASHING:
It occurs in a valve, when the pressure at vena contract drops to less than the inlet
pressure P1, outlet pressure P2 is also less than the fluid pressure. The fluid enters the
valve as a liquid and exits as a vapor. The inlet pressure P1 is less than vapor pressure.
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EFFECTS:
High velocities and mixed phase flow at generated by the expansion of liquid into
vapor. Which can cause erosion and tuning of pressure boundary walls. Flashing
generate excessive vibration associated with high velocity flow.
PREVENTION:
By reducing velocity and using erosion material or effective design can minimize
the damage from flashing.
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REVIEW QUESTION :
PART- A ( 2 marks )
1. State the Control Valve Characteristics .
2. Define Actuator.
3. Mention the different Signal Convertors.
4. What can limit the flow through the control valve.
5. Give the output range of P to I convertor.
6. List the 3 major parts of a Pneumatic Control Valve.
7. What is I to P convertor.
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2. Explain Electric Motor Actuated Control Valve.
3. Explain Signal Converter with Diagram.
4. Describe about the Effect of Flashing and Cavitations in Control Valve.
5. Explain the working of an Electro Pneumatic Actuator with a Diagram.
6. What is Valve Positioner?. List the different types of Valve Positioner and
mention its Application.
7. Describe in detail the working of Split Range Control Valve.
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Feed forward control system, Feed forward control of heat exchanger. Comparison of
feedback control system and feed forward control system. Ratio control – examples –
Cascade control – cascade control of heat exchanger –cascade control of distillation
column. Direct digital control (DDC) of single loop, direct digital control with multiple
control loops.
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--- 5.1 ADVANCED CONTROL SYSTEMS
The feedback control configuration involves one output (measurement) and one
manipulated variable in a single loop. The other control configurations mentioned above
may use more than one measurement and one manipulation or one measurement and
more than one manipulated variables. In such cases control systems with multiple loops
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may arise. These control systems involve loops that are not separate but share either the
single manipulated variable or the only measurement.
The systems with a single manipulated input and single controlled output are
called ‘Single-Input Single Output’ systems (SISO). Chemical processes usually have two
or more controlled outputs, requiring two or more manipulated variables. Such control
systems are called ‘Multiple Input and Multiple Output’ systems (MIMO).
The feed forward control configurations react to variations in disturbance variables (or
set point), predict the disturbance’s effects and take corrective action to eliminate its
impact on the process output. Therefore, the feed forward controllers have the
theoretical potential for perfect control. But, as it is difficult to measure all possible
disturbance variables and to predict their effect quantitatively, feed forward control is
generally used along with feedback control.
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Disturbances
Manipulated variable
Process
Controlled output
Controller
Disturbances
Controller
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Manipulated variable
Process
Controlled output
Fig 5 .1 shows a typical schematic of a feedback control system. In comparison to that we can
see the general form of a feed forward control system in Fig 5.2. It measures the disturbance
directly and then it anticipates the effect that it will have on the process output.
Subsequently, it changes the manipulated variable by such an amount as to eliminate
completely the impact of the disturbance on the process output (controlled variable).
Control action starts immediately after a change in the disturbance has been detected. It is
clear from the Figs. 5.1 and 5.2 that feedback acts ‘after the fact’, in a compensatory manner,
whereas feed forward acts ‘beforehand’ in an anticipatory manner.
1. A heat exchanger exchanges heat between two streams, heating one and cooling
the other.
2. Heat can be transferred between the same phases (liquid to liquid, gas to gas etc)
or phase change can occur on either the process side (condenser, evaporator, reboiler
etc) or the utility side (steam heater) of the heat exchanger.
3. The objective is to keep the exit temperature of the liquid constant by
manipulating the steam pressure.
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5. The controller acts according to which disturbance changed value. Fig 5.4
represents the general case of feed forward control with several loads (disturbances)
and a single controlled variable.
6. The major components of load are entered into a model to calculate the value of
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the manipulated variable required to maintain control at the set point.
Advantages
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Ratio control is a special type of feed forward control where two disturbances are
measured and held in a constant ratio to each other. Many industries require feed in
specific ratio, examples being air –fuel ratio in burner’s reactants ratio to blending unit
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and reactors.
It is mostly used to control the ratio of flow rates of two streams. Both flow rates
are measured but only one can be controlled. The stream whose flow rate is not under
control is usually referred to as ‘wild stream’.
Figure 5.5 shows two different ratio control configurations for two streams. Stream A is
the wild stream. In configuration 1 we measure both flow rates and take their ratio. The
ratio is compared to the desired ratio (setpoint) and the deviation (error) between the
measured and desired ratios constitutes the actuating signal for the ratio controller.
Fig 5 .5 Configuration 1
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Fig 5 .6 Configuration 2
A most common ratio control is to control the ratio of two reactants entering a reactor at a
desired value. In this case, one of the flow rates is measured but allowed to flow, that is
not regulated, and the other is both measured and controlled to provide the specified
constant ratio.
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Furnace
Fuel flow
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In a cascade control configuration we have one manipulated variable and more than
one measurement. In the scheme there will be two controller’s namely primary controller
and secondary controller. The output of the primary controller is used to adjust the set point
of a secondary controller, which in turn sends a signal to the final control element (may be
control valve). The process output is fed back to the primary controller, and a signal from an
intermediate stage of a process is fed back to the secondary controller. The block diagram of
such a cascade control system is shown in figure.5.9
Two measurements are taken from the system and each used in its own control loop. The
outer loop (primary controller) controller output is the set point of the inner loop
(secondary controller). Thus, if the outer loop variable changes, the error signal that is input
to the controller effects change in set point in inner loop. Even though the measured
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value of the inner loop is not changed, the inner loop experiences an error signal and thus
new output virtue of the set point change. Cascade control generally provides better control
of the outer loop variable than is accomplished through the single variable system.
Final control
Inner set
Inner
Process
Controller
Inner variable
Outer set point measurement
Outer
Controller
Outer
variable
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1. A heat exchanger exchanges heat between two streams, heating one and cooling
the other.
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generates signal which acts as the set point to the flow controller.
6. Flow controller closes the control valve that decreases the flow of heating liquid
so as to get desired heating effect.
7. Similarly if the heating fluid temperature falls below the desired value, the control
valve opens with increases the flow of heating fluid so as to get the desired heating effect.
DISTILLATION COLUMN
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1. Reboiler: The liquid leaving the column bottom is heated in a reboiler. A reboiler
is a special type of heat exchanger used to provide the heat necessary for distillation.
2. Part of the liquid is vapourised and returned into the column as boil-up. The
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remaining liquid is withdrawn as a bottom product.
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In the past computer was not directly connected to the process but used for
supervision of analog controllers. The emergence of economical and fast microprocessor
has made analog controllers to be replaced y digital computers as the same functions
can be performed by them in more efficient and cost effective way.
Direct digital control means the computer directly controlled the process
The DDC directly interface to the process for data acquisition and control
purpose. Therefore DDC should have
1. Necessary hard ware for directly interfacing and reading the data from
process.(Eg:-Opto isolator, Signal conditioner ,ADC)
2. Memory and arithmetic capability to execute P, PI, and PID control strategy.
3. Necessary hardware to control the process(Eg:- DAC, I to P converter)
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1. Figure shows the hard ware elements of a single loop control system using digital
computer.
2. The measurement signal from the sensor or transducer is sampled at prespecified
intervals of time using a simple sampler.
Set point
----------------
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A/D Transducer Measuring
5. Figure shows the use of a single computer (CPU) to control outputs. When a
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digital computer has assumed all control actions of a conventional controllers.
6. Rapid technological developments in digital computing systems coupled
with significant reduction in their cost have had a prefound effect on how
chemical plants can and should be controlled.
7. Already large plants such as petroleum refineries, ethylene plants, ammonia
plants and many others are under digital computer control.
8. The benefits have been substantial both in terms of operating cost and interms
of operational smoothness and safety
REVIEW QUESTIONS:
PART- A (2 marks)
1. Expand SISO&MIMO
2. What is a feed forward control system?
3. List the advantages of feed forward control system.
4. List the dis-advantages of feed forward control system.
5. What is a ratio control system?
6. List the any four applications of ratio control system
7. What is a cascade control system?
8. List the advantages of cascade control system.
9. What is a direct digital control?
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