Process Control Elements
Process Engineering II (EI - 309)
Lalu Seban Assistant Professor, Dept. of Electronics & Instrumentation Engineering, National Institute of Technology Silchar Lecture 9 (Module - II)
UNIT II (Lectures - 4) PROCESS CONTROL ELEMENTS: Signal conversion - I/P, P/I Converters, Pneumatic and Electric actuators, Valve Positioner, Control Valve, Characteristics of Control Valves, Types of control valves, Control valve sizing, cavitation and flashing.
Once again to the basic
In simple words
Measure the PV Evaluate (SP-PV) Decision (by controller) Action (by FCE)
In microscopic view
Language problem
Synchronization between sensor and controller, controller and FCE etc. FCE should understand what Controller speaks We need a translator (I/P, I/V, P/I) Better avoid mediators in real life
Process Control Elements
By Application Sensors A/D, D/A Converters I/P, P/I, V/I, I/V Converters Actuators/FCE
Process Control Elements
Depending on the energy source Hydraulic (pressurized uncompressiblle fluid) Pneumatic (compressed air) Electric (current, voltage)
Electric Vs Pneumatic Vs Hydraulic
Advantages
ELECTRIC
Accurate position Suit to advance control No tubing
PNEUMATIC
Inexpensive Fast No pollution No return line No stall damage
HYDRAULIC
Large capacity Locking capability Self lubricating Easy to control Smooth operation
Disadvantages
Low speed Expensive Unsafe Need breaker Overheating Low accuracy Noise pollution Difficult speed control Need infrastructure Expensive Leakage problems Difficult speed control Need return line Need infrastructure
I to P convertor
Controller speaks in I (4-20 mA) FCE understands only P (3-15 Psi) So we take the help of a mediator called I/P converter
Air supply 20 psi Current 4 to 20 mA
I/P
Pneumatic 3 to 15 psi supplied to FCE
I to P convertor
P to I convertor
Transmission over large distances Input to an electronic logger or computer Input P (3-15 Psi) Output I (4-20 mA) Make use of pressure capsule
P to I convertor
Problems.
The electrical (4-20mA) temperature transmitter is calibrated for a temperature range of 500 to 750 Kelvin. Range and Span ? Find the output of transmitter when temperature is
400K, 500K, 600K, 700K, 750K, 1000K
Is it clear
0 to 150 Psig, the range is 0 to 150 Psig, 0 for the 0%(4mA) and 150 for the 100 % (20mA), the span is 150Psig 20 to 200 Psig, the range is 20 to 200 Psig, 20 for the 0%(4mA) and 200 for the 100%(20mA), the span is 180Psig 40 to 350 F, the range is 40 to 350 F, 40 for the 0%(4mA) and 350 for the 100 % (20mA), the span is 310F
Problems.
If the input to an I/P converter is 10mA, what will be its output? 0mA, 4mA, 10mA, 12mA, 20mA Represent every signal in percentage and then proceed
Is it clear.
Signal (x) to (%)
x - xmin (%) = X 100 xmax - x min
(%) to Signal (x)
(%) x = xmin +(xmax - x min ) X 100
Process Control Elements
Process Engineering II (EI - 309)
Lalu Seban Assistant Professor, Dept. of Electronics & Instrumentation Engineering, National Institute of Technology Silchar Lecture 10 (Module - II)
Final Control Element
equipment to convert the control signal (generated by controller) into the action needed to correctly control the process The final control element adjust the amount of energy/mass goes into or out from process as commanded by the controller
Hydraulic Actuators
Using pressurised liquid for doing work Pressure in whole liquid remain equal Applications requiring large forces and precise control vehicle power steering and brakes, hydraulic jacks and heavy earth moving machines
Final Control Elements
Hydraulic Pneumatic Electric
Hydraulic Actuators
F1 P1 x A1 F 2 P 2 x A2 P1 P 2 F 2 A2 32 2 9 F1 A1 1
Electronic FCEs
Heater Blower Motors Solenoid valves
Electronic FCEs
Heater Blower Motors stepper, AC, DC Solenoid valves
Solenoid
When the coil is energized the core will be pulled in
core
coil
SOLENOID
coil
core
Solenoid
Solenoid
Control Valves
mechanism to regulate flow by opening or closing based on signal from controller
Control Valves
Linear or Rotary motion valves Electric or Pneumatic valves Air to open or Air to close valves Manual or Automatic valves Linear or Quick opening or Equal percentage valves
Linear Motion valves
closure member moves in a straight line to regulate flow Gate valve Globe valve Diaphragm valve
Rotary Motion valves
closure member moves in an angular or circular path to regulate flow Plug valve Ball valve Butterfly valve Quarter Turn Valves: rotary valves which moves from fully closed to fully open in a a quarter turn
Remember
Rotary valve : turn Clock-wise to Close
Quarter turn valve : perpendicular to pipe (line) to Close
Based on actuation
Manually turning using motors Using pneumatic pressure
air to open air to close
Valve Components
Valve Body
is the first boundary of a pressure Valve framework that holds all the parts together ends are designed to connect the Valve to the piping
Valve Disk
part which regulate flow, depending on its position. With the Valve closed, full system pressure is applied across disc valves named disc design linear motion gate, globe rotatory motion butterfly, ball
Valve Seat(s)
ensures the seating surface for the disk fine surface finished seating for good sealing one seat globe valve two seat gate valve
Valve Stem
Valve stem provides the necessary movement to the disc, plug or the ball one end connected to the actuator second end to disc linear or rotatory movement
Valves by construction type
The valving element rotates in the passageway to stop flow. Eg.: Ball Valve, Butterfly Valve
Valves by construction type
The valving element acts as a 'seal' or 'plug' in the passageway to stop flow. Eg.: Globe Valve
Valves by construction type
The valving element is 'inserted' into the passageway to stop flow. Eg.: Gate Valve
Valves by construction type
The valving element is 'pinched' against the passageway from the outside to stop flow. Eg.: Diaphragm Valve
Ball Valve
Butterfly Valve
Globe Valve
Gate Valve
Diaphragm Valve
Valve - Flow characteristics
Linear, Equal %, quick (fast) opening % flow Vs % opening
Valve - Flow characteristics
based on trim (disc, seat)
Valve Positioner
static friction differential pressure another control system within FCE !!
