OGIM Formation

Module Instrumentation _Package 4

FINAL CONTROL ELEMENTS

Objectives:
To understand the basic theory of design and principle of-
operation of Final control elements.
To understand the components of a Control valve.
To understand the working of different control valves.
To understand the working of Other Control elements.

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 Expected Learning Outcomes
1. Awareness:-
♦ A general understanding of the working of Final control
elements.
2. Underpinning Knowledge:-
♦ Basic knowledge of Control valves and Other Final control
elements.
3. Developing Practical Skills:-
♦ Provide support to Instrument Technicians.
♦Correct & specific reporting of Instrumentation problems.
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 INTRODUCTION

FINAL CONTROL ELEMENT PERFORMS

THE FINAL CORRECTIVE ACTION IN THE
CONTROL LOOP.

Final control elements mainly includes

control valves, electric motor, speed
controller of an electric motor ( variable
speed motor), speed controller ( governor)
of gas turbine, solenoid valves, etc.

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What is a final control element?
It is the mechanism which changes the value of the
manipulated variable in response to the output signal
from the control unit.
It consists of two parts:
1. An actuator and linkage which translates the
controller output signal into sufficient power and
motion to operate the final control element.
2. The final control element which is a device to adjust
the value of the manipulated variable by, controlling
the flow of the control agent.

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 CONTROL VALVE

What is a control valve as used in a control loop?

It is any device by which the flow of liquid, air, or other gas, loose
material in bulk, etc., may be started, stopped or regulated by a
movable part which opens or obstructs passage.
IT IS AN ENGINEERED OBSTRUCTION IN A PIPE.

Where are the control valves mostly used?

Control valves are widely used in regulating pressure, temperature
and rate of flow of water, steam, chemicals, petroleum products -
about every thing that flows.
VALVES ARE THE MOST COMMON and BASIC CONTROL
ELEMENT.

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CONTROL VALVE Air in

Diaphragm
spring
stem
travel indicator

scale
gland

plug
body

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 BASIC ELEMENTS OF A CONTROL VALVE

CLASSIFIED INTO 3 PARTS:-

1. BODY (body, bonnet, packing,bottom cap & gasket)

2. TRIM (all the removable internal parts which comes in

contact with the flowing fluid)

3. ACTUATOR (stem, packing gland, grease cage, packing

retainer ring, stem lock pin & guide bushing)

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 VALVE SINGLE-SEATED
Perpendicular Single-Seated Valve
Straight Single-Seated valve

Sealing

Spring

P2

P2
P1

P1

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 VALVE SINGLE-SEATED
Three-way Valve

A AB

B
The perpendicular valve and three-way valve are, in principle 9
similar.
 DOUBLE SEATED VALVE

Large valve and large delta-pressure exert very high force on the plug.
The force may open the valve.
This may create problems in the valve operation.
A better solution is double seated valve.
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 BUTTERFLY VALVE

For large pipe diameters and

for small pressure differences
a butterfly valve is often used.
These are cheaper valves.
Control characteristics are poor.

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 AIR ACTUATOR

Pilot Pressure

Diaphragm

Spring

Pilot Pressure
Valve shaft

Figure - 1 Figure - 2
SHAFT MOVES DOWN WHEN SHAFT MOVES UPWARDS
PRESSURE INCREASES. WHEN PRESSURE INCREASES.

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VALVE ACTIONS

Air to close valve

Fail open valve

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VALVE ACTIONS

Air to open valve

Fail closed valve

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VALVE ACTIONS

Air to open valve

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VALVE ACTIONS

Air to close valve

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Selection of a valve depends mainly on the type of process and the
main criteria is safety of the equipments and operating personnel.
Most of the pressure control valves will be air fail open valve. The
idea behind is to avoid over pressurising in case of the air failure
or a diaphragm rupture.
Anti-surge control valves for gas compressors are air fail open
valve. This is to protect the compressor by avoiding the closing of
the valve when air or diaphragm fails
In the case of a control valve which operates from a high pressure
to a lower pressure, we prefer an air fail close valve to avoid
overpressurising of the downstream facilities.
The level control valve of bulk separators will be an air fail close
valve. This is to protect Surge tank from overpressurising incase
of a failure of the separator LCV
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 PC
Air fail open valve Gas to flare

PCV
Gas to Compressor
Bulk separator
LC

LCV Surge tank

Air fail close valve

SELECTION OF VALVE ACTION IS ON PROCESS REQUIREMENT. 18

 VALVE SYMBOLS

Air fail open Hand valve

Air fail close

Back pressure 3 way valve

regulator Air fail stay in position 19
 Air operated Control valves can be mainly of three type

•Air to open :
•These valves opens when air pressure is given to the diaphragm
and closes when air pressure is released. These valves are also
called air fail close valve.

•Air to close:
• These valves closes when air supply is given and opens when
air pressure is released, also called air fail open valve.

•Air fail stay in position:

• On air failure this valve retains the same position it had at
the time of air failure.
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 Positioner
Input from I/P
supply air
output to valve

Uses of positioner
•Helps in keeping the valve at the correct operating
position.
•Boosts the pressure and volume of the air coming out from
the I/P converter before given to the valve.
•Possible to reverse the output of the I/P before given to the
valve diaphragm.
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OTHER FINAL CONTROL ELEMENTS

SOLENOID VALVE
ALARMS
PUMPS
ELECTRICAL SWITCH
Etc.

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 Solenoid valve in de-energised
energised condition
condition

Air in

Bleed off 23
WhenSolenoid
the solenoid
is aniselectromagnet
energised, it lifts up the iron core and
this opens the inlet line and close the bleed line. This supplies
It is made by winding a wire in the form of a coil around an
air to the control valve diaphragm.
iron piece
When it is de-energised the magnetic field disappears and the
When electric current is passed through a solenoid, a
iron core moves down. This closes the inlet and opens the
magnetic field is created around the coil. This magnetic field
bleed line. Air from the control valve diaphragm is bled-off
attracts the iron core.
and the control valve closes.
The valve is connected to the iron core by a rod.
Solenoid valves are very widely used in petroleum industries.
havemainly
Solenoid valves are three ports connected
used to to toinlet,
supply air outlet
control valve
and bleed-off lines.
diaphragms.
They are ON-Off valves.

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 ALARMS

Pressure
Switch

ALARM SYSTEM

Light Horn

Accept Reset Test

Warning signal is operated in the control room.

It can be both audible and visual.
Visual is amber light, which may flicker.
Audible signal can be given by a horn.
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 PUMPS

Drain Vessel
LC H
L

Pumps also occasionally function as final elements of automatic control

system. Drain vessel Pumps are examples.
High level initiate the start of the Pump.
Low level initiate the stop.

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 ELECTRIC SWITCH
ELECTRIC WATER HEATER
CONTACTOR SWITCH AS
FINAL CONTROL ELEMENT

Temperature switch
or Thermostat

Contactor
Switch Control
(Final control Supply
element)

HEATING ELEMENT

Automatic hot water system’s heating element is simply a remote-controlled

electric switch that controls current to the heating element.
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