[CHE 239 ]

PROCESS CONTROL & INSTRUMENTATION

PR E PAR E D BY :
Nurul ‘Uyun Binti Ahmad
Azmi Bin Mahmood
Faculty of Chemical Engineering, UiTM Bukit Besi, Terengganu
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Final Control Elements in
Control System
C HA PT E R
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Contents :
 3.1 Control/Solenoid valve
 3.2 Metering pumps
 3.3 Variables speed drives

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 Aim
Aim
To explain the principles of
measurement of various instruments
and the basic component used in
process control system.

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 Final control element
 Part of a control system which implement
the control decision made by the
controller

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Types of Final control element

1. Control Valve
2. Variable Speed Drive, VSD
3. Metering Pump

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Elements of the final control operation

Control
signal Signal conversion Actuator

Final
Control
Element

Process
 Signal Conversions
 This step refers the modifications that must be made to
the control signal to properly interface with the next
stage of control-that is, the actuator.

 The devices that perform such signal conversions are

often called transducers because they convert control
signals from one form to another, such as current to
pressure, current to voltage, and the like.
Signal Conversions

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3.1 CONTROL VALVE

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 What is a Control Valve?
 The most common final control
element in the process control
industries.

 80%of final control element found in

chemical process industries.

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 What is a control valve?

 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

Three main parts

Valve's actuator
Valve's positioner
Valve's body

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Control Valve Assembly

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

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 Pneumatic 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

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Pneumatic Actuator

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 Electric Valve Actuator
 powered by motor that converts electrical
energy to mechanical torque
 Solenoid, ac motor, dc motor, stepping motor

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 Hydraulics Actuator
 Use liquid pressure rather than gas pressure to
move the valve mechanism
 Commonly use a piston rather than a diaphragm
 Handle large pressure

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 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

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Positioner

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 Types of Control Valve

Control
Valves

Rotary Linear
Motion Motion

Butterfly Ball Plug Globe

valves vales valves Valves

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Types of Control Valve
globe valve

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Types of Control Valve – ball valve

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Types of Control Valve – butterfly valve

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 Safety consideration

Air-to-open (ATO) Failure close

Air-to-close (ATC) Failure open

Safety consideration
Valve action:
Air-to-close (ATC or AC)
 Or Fail open (FO). Use to
allow flow of fluid during
loss of pneumatic air supply.
This action may save
overheating of temperature
related processes such as
catalyst heating or heating of
polymerization process.
Safety consideration
Valve action:
Air-to-Open (ATO or AO)
 Or Fail closed (FC). Use to
prevent flow when no
pneumatic air supply. This
action may prevent
hazardous chemical or
flammable fluid from
endangering lives.
Safety consideration

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 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 30
 Solenoid valve
 A solenoid valve is an electromechanically operated
valve. The 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.

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Solenoid valve

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

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Metering Pumps vs. Centrifugal Pumps: Flow vs. Pressure

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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

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Functioning

 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.

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There are different technologies to feed the dosing medium. According
to the feeding-technology used, metering pumps can be categorized as
follows:

 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

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Peristaltic Pump Internal Components

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Piston Pump Internal Components

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Diaphragm Pump Internal Components

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Solenoid-actuated Diaphragm Metering Pump

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 The Selection Guide for Metering Pumps supports you
in pre-selecting the right pump type for your application
in four steps:

 Identify the required feed rate for your application in

liters per hour [l/h]
 Identify the back pressure of your application [bar]

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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

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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 as suspended solids and viscous fluids
 Can handle high suction lift applications
 High pressures up to 3,000 psi can be reached
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3.3 VARIABLE SPEED DRIVE

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 WHAT IS
VARIABLE SPEED DRIVES?
• 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.).

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Type of 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 sheaves

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 match
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 electrical supply
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 to VSD

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Component of VSD
1. Rectifier- diodes to convert ac power to dc power

2. DC Bus – capacitor to store power and smooth

out voltage ripples or power distortions.

3. Inverter – IGBT (insulated gate bipolar transistor)

to convert dc to variable ac, pwm (pulse width
modulation) to simulate sine wave

4. Regulator/controller

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VSD

dc bus

Closed loop VSD system

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 The speed of the rotating electric field within the
induction motor.
Synchronous Speed = 120 x frequency
no. of motor poles

AC Line Motor

Diode DC Bus IGBT

Rectifier Filter Inverter

• Diode rectifier converts AC line voltage to fixed voltage DC.

• DC voltage is filtered to reduce current ripple from rectification.
• Inverter changes fixed voltage DC to adjustable PWM AC voltage.
IGBT=Insulated Gate Bipolar Transistor
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 VFD Fundamentals
A variable frequency drive converts incoming 50 Hz utility
power into DC, then converts to a simulated variable
voltage, variable frequency output.

AC DC AC

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

50 Hz Zero - 120 Hz

ABB
VFD
To
Motor
Zero - 120 Hz
Electrical Energy

VFD
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 How Often You Switch From Positive
Pulses To Negative Pulses Determines
The Frequency Of The Waveform

Positive
+
DC Bus

Voltage
Negative
-
DC Bus

RECTIFIER INVERTER Frequency

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Frequency = 30Hz

Frequency = 60Hz

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 PWM (Pulse Width Modulation)

The blue sine-wave is shown for comparison purposes only. The drive
does not generate this sine wave.
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Various Types of Driven Equipments
1. Pump;
2. Fan;
3. Compressors;
4. Conveyers;
5. Mill;
6. Crusher;
7. Crane;
8. Hoist;
9. Traction;
10. Elevator
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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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Affinity Laws, Centrifugal Pumps
1. Flow is proportional to speed
2. Pressure varies with square of speed
3. Power varies with cube of speed
So significant energy saving with VSD at lower pump speed

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FINANCIAL JUSTIFICATION

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THANK YOU!

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Reference
 Process Control: Designing Processes
And Control Systems For Dynamic
Performance . Thomas E. Merlin
(2000) Mcgraw-hill Higher Education.

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