Process Control Lecture 9 (M2)
Process Control Lecture 9 (M2)
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.
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
By Application Sensors A/D, D/A Converters I/P, P/I, V/I, I/V Converters Actuators/FCE
Depending on the energy source Hydraulic (pressurized uncompressiblle fluid) Pneumatic (compressed air) Electric (current, voltage)
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
I/P
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
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.
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
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
Electronic FCEs
Solenoid
coil
SOLENOID
coil
core
Solenoid
Solenoid
Control Valves
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
Remember
Based on actuation
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
The valving element rotates in the passageway to stop flow. Eg.: Ball Valve, Butterfly Valve
The valving element acts as a 'seal' or 'plug' in the passageway to stop flow. Eg.: Globe Valve
The valving element is 'inserted' into the passageway to stop flow. Eg.: Gate Valve
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 Positioner