[CHE 239 ]

PROCESS CONTROL & INSTRUMENTATION

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 3
Final Control Elements in
Control System
CHAPTER

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Contents :
 3.1 Control/Solenoid valve
 3.2 Metering pumps
 3.3 Variables speed drives

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 AIM

To explain the principles of measurement of various

instruments and the basic component used in
process control system
 Final Control Element - Action
• Every process control loop contains a final control element,
the device that enables a process variable to be manipulated.

• For most chemical and petroleum processes, the final control

elements adjust the flow rates of materials, and indirectly, the ra
energy transfer to and from the process.

• There are many different ways to manipulate the flows of material

and energy into and out of a process; for example, the speed of a
pump drive,screw conveyer,or blower can be adjusted.

• However, a simple and widely used method of accomplishing this

result with fluids is to use a control valve, also called an automatic
control valve.
3.1 Control Valve
 The most common final
• Sym
control element in the process
control industries.

 80% of final control element found

in chemical process industries.

• The control valve manipulates

a flowing fluid, such as gas, steam,
water, or chemical compounds, to
compensate for the load
disturbance and keep the =
regulated process variable as
close as possible to the desired set
point.
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Parts of Control Valve
Construction
The control valve actuator

• The purpose of the valve actuator is to accurately locate the valve plu
in a position dictated by the control signal
The control valve actuator

• air pressure actuator is the most common to adjust the position of

control valves
• The controller signal m(t) is in percent controller output (%CO), as
opposed to mA or psig
• the actuator convert the controller output m(t), into the valve
position, vp(t)
• The valve position usually expressed as a fraction -varies between
zero and unity.
• When the valve position is zero - the valve is closed and the
flow is zero
• When the valve is unity -the valve is fully opened and the
flow is maximum.
• For full range valve actuator, a 1% change in controller
output results 0.01 change in fraction valve position.
• Most control valves use a full range actuator
Pnuematic Actuator

 Use air pressure

pushing against either
a flexible diaphragm
or a piston to move
a valve mechanism.
 More than 90%
actuator in use are
pneumatic
Pneumatic Actuator
Electric valve actuator

 powered by motor that converts electrical energy to mechanical

torque
 Solenoid, ac motor,dc motor, stepping motor
 Hydraulic Actuator
 Use liquid pressure rather than gas pressure to move the va
mechanism
 Commonly use a piston rather than a diaphragm
 Handle large pressure
Positioner
 instruments that
help improve
control by
accurately
positioning a control
valve actuator in
response to a
control signal

 receive an input signal

either pneumatically
or electronically and
provide output power
to an actuator
• When the valve position is zero - the valve is closed and the
flow is zero
• When the valve is unity -the valve is fully opened and the
flow is maximum.
• For full range valve actuator, a 1% change in controller
output results 0.01 change in fraction valve position.
• Most control valves use a full range actuator
Positioner
Types of control valves
Types of control valve - GLOBE
Types of control valve - BALL VALVE
Types of Control Valve - BUTTERFLY VALVE
Safety Considerations
• What do I want to do when energy supply fails?
• When the safest position of the valve is the closed
position
-specify a ‘fail-closed’ (FC) valve
-this valve required energy to open and is also called ‘air-to-
open’ ( TO) valve
• When the safest position of the valve is the opened
position
-specify a ‘fail-open’ (FO) valve
-this valve required energy to close and is also called ‘air-to-
close’ ( TC)
 Safety consideration

Air-to-open (ATO) Fail Close (FC)

Air-to-close (ATC) Fail Open (FO)

 Selection Criteria
Valve action: ATO vs. ATC
 Air-to-closed (ATC) or Fail open (FO). Use  Air-to-open (ATO) or Fail closed (FC). Use to
to allow flow of fluid during loss of prevent flow when no pneumatic air supply.
pneumatic air supply. This action may save This action may prevent hazardous chemical or
overheating of temperature related flammable fluid from endangering lives.
processes such as catalyst heating or heating
of polimerization process.

compare

compare
compare
compare
Safety considerations
Flow characteristics of control valves
• Quick Opening: Quick open plugs
are used for on-off applications
designed to produce maximum flow
quickly
• Linear: produces equal changes in
flow per unit of valve stroke regardless
of plug position, used where valve
pressure drop is a major portion of
the total system pressure drop
• Equal Percentage: change in flow
per unit of valve stroke is directly
proportional to the flow occurring
just before the change is made,
generally used for pressure control
 Solenoid valve
 A solenoid valve is an
electromechanically operated
[Link] valve is controlled by an
electric current through a solenoid: in
the case of a two-port valve the flow
is switched on or off; in the case of a
three-port valve, the outflow is
switched between the two outlet
ports. Multiple solenoid valves can be
placed together on a manifold.

 Industrial uses for the solenoid control

valve are many and include accurate
control of process water for batching,
mixing, washing, blending or other on-
off type uses.
3.2 METERING PUMP

• A metering pump moves a precise volume of liquid in a

specified time period providing an accurate flow rate.

• Delivery of fluids in precise adjustable flow rates is

sometimes called metering.

• The term "metering pump" is based on the application or use

rather than the exact kind of pump used, although a couple types
of pumps are far more suitable than most other types of pumps.

• The metering pump is a positive displacement chemical dosing

device with the ability to vary capacity manually or automatically
as process conditions require.

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 METERING PUMP

• It features a high level of repetitive accuracy and is capable of pumpin

wide range of chemicals including acids,bases,corrosive or viscous
liquids and slurries.

• The pumping action is developed by a reciprocating piston which is

either in direct contact with the process fluid, or is shielded from the
fluid by a diaphragm.

• Diaphragms are actuated by hydraulic fluid between the piston and the
diaphragm.
Metering pumps are generally used in applications where one or more of
the following conditions exit:

 Low flow rates in mL/hr or GPH are required

 High system pressure exists
 High accuracy feed rate is demanded
 Dosing is controlled by computer,microprocessor,DCS,PLC,or
• flow proportioning
 Corrosive,hazardous,or high temperature fluids are handled
 Viscous fluids or slurries need to be pumped
Metering Pumps [Link] Pumps:Flow [Link]
Function of metering pump

 Metering Pumps (oscillating positive displacement pumps)

suck in a defined fluid volume with the back- stroke of the
displacer and press it into the dosing line with the pressure
stroke.

 The metering capacity can be regulated by adjusting the

stroke volume and the dosing strokes per time unit.

 Thus, a constantly exact dosing is achieved remaining

• constant even at varying counter-pressures.
Categories of metering pump

 Mechanically actuated diaphragm metering pumps

 Hydraulically actuated metering pumps
 Plunger metering pumps
 Peristaltic pumps

Another way of categorizing metering pumps is according to the pump drive

 Solenoid-driven metering pumps

 Motor-driven metering pumps
 Air operated metering pumps
 The Selection Guide for Metering Pumps supports you in pre
selecting the right pump type for your application in four
steps:

i. Identify the required feed rate for your application in liters per
hour [l/h]
ii. Identify the back pressure of your application [bar]
Peristaltic Pump Internal Components

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Piston Pump Internal Components

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Diaphragm Pump Internal Component

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Solenoid-actuated Diaphragm Metering Pump

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Applications
 Chemical processing
 Food and beverage dispensing
 Cosmetics industries
 Medical applications where that require sterilization
 Municipal applications for dispensing PH additives
 Agricultural
 Oil & gas
 Power generation
 Pharmaceutical & biotechnology
 Textile
 Water treatment
Advantages
 Optimal capacity adaptation to widely varying
production processes
 Variable stroke length for each pump allows independent
flow rate adjustment of each pump component
 Variable speed drive allows flow rate variations while
• maintaining constant proportions
 Accuracy, linearity and repeatability
 Can generally handle abrasive and corrosive liquids as well
suspended solids and viscous fluids
 Can handle high suction lift applications
 High pressures up to 3,000 psi can be reached
3.3 Variable speed drive

• A generic term which

applies to devices that
control the speed of
either the motor or the
equipment driven by the
motor (fan, pump,
compressor,etc.).
Type of Speed Variable Drives

1. Mechanical variable speed drives

2. Hydraulic variable speed drives

3. Electrical variable speed drives

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1. Mechanical variable speed drives

1. Belt and chain drives with adjustable diameter sheav

2. Metallic friction drives

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• Use mechanical means to convert a fixed-speed
motor output into a variable speed output.

• Use of adjustable belt and pulley mechanisms or

through metal roller mechanisms with adjustable
diameters.

• Have inherent mechanical losses.

• Not as energy efficient as electronic/electrical

devices.

• Additional losses can be up to 20% more than

electronic devices.
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2. Hydraulic variable speed drives

• Use hydraulic oil as A medium through which the

torque is transmitted to the output.

• Have higher inherent mechanical and hydraulic

losses than mechanical variable speed drives

• Not as energy efficient as electrical vsds.

• Types- hydrostatic drives, hydrodynamic drives and

hydro-viscous drives.

• Hydraulic variable speed drives have fairly specific

uses, for example in the automatic transmission
system of motor cars.
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3. Electrical variable speed drives

• Electronic device used to control the speed and

torque of an electrical motor, achieving a better matc
with the process requirements of the machine it is
driving.

• The most common vsd in industries since electric

motor is the workhorse of industries - motor account
for 2/3 of energy used in industries

• Other names for a electrical vsd are variable

frequency drive (vfd), adjustable speed drive
(asd), adjustable frequency drive (afd), ac
drive, microdrive,and inverter.
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 CONTROL PRINCIPAL OF VSD

• A VSD works by converting the incoming electricalsupply

of fixed frequency into a variable frequency output.

• So a low frequency for a slow speed, and a higher

frequency for a faster speed.

• The output can also be changed to enable the motor to

generate more or less torque as required.

• So, the motor and drive combination might be used for

turning a large load at fairly slow speeds, or turning a
lighter load at high speeds, maximising efficiency.

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VSD

VSD

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Motor connected toVSD

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VFD Fundamentals
A variable frequency drive converts incoming 50 Hz utilit
power into DC, then converts to a simulated variable
voltage, variable frequency output.

AC DC AC

50 Hz Power RECTIFIER
(AC - DC)
INVERTER
(DC - AC)

50 Hz Zero - 120 Hz

ABB
VFD
To
Motor
Zero - 120 Hz

VFD
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Why
Electrical Variable Speed Drives?
1. Save energy and improve efficiency
2. Process controllability
3. Reduced mechanical wear and shock
4. Improved power factor
5. Coordination of motion on various shafts
6. Easy interfacing with automation systems

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FINANCIAL JUSTIFICATION

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THANK YOU