Measuring & Control

DAY 16-20
SAO-08
By:
Muhammad Ashfaq Ch
Tehseen Ahmad
 Instrument Signals
Signals
Signal are used to provide communication between
instruments of a control system. There are four
principal types of signals.
 Pneumatic Signal
The Pneumatic or air signal is actually base on air
pressure which normally ranges between 3 PSI to
15 PSI. Its Symbol is:
 Hydraulic Signal
The Hydraulic signal is usually transferred from one
location to the other by the Differential Pressure of
oil. Its range is normally 1.5 ~4.5 Kg/cm2 & symbol
is:
 Signals
 Electrical Signal (Volt, Current, Resistance)
The Electrical / Electronic signal normally range
between 4mA to 20mA (Current), 0V to10V (Voltage),
RTD Ω range (Resistance). Its symbol is:

 Digital Signal
The digital signal transferred in the form of zero and
one (Binary). This type of signal is commonly used in
computers and modern control system (DCS, PLC). Its
range is normally K. bytes/sec, M. bytes/sec. Its
symbol is:
 Signal Conversion
 One type of signal can be converted into another
type of signal. for example Pneumatic signal can be
converted into Electrical signal and vice versa.
 E / P’s or I / P’s
To convert the electrical signal (4~20mA) into a
corresponding Pneumatic signal (3~15 PSI) for
Valve operation.
Signal to Actuator

Actuator 4 ~ 20 mA
Signal

E/P
3 ~ 15 PSI 20 PSI

Positionar
Air supply
100 PSI
Air supply
Feed Back 100 PSI
Link

Valve
Steam
 Signal Conversion
 Positionar
It is a device to operated by pneumatic instrument
signal, but with separate air supply. Is used to
provide the necessary air pressure to the control
valve actuator for accurate positioning in accordance
with the demands of the loop controller. They are
mechanically connected to the valve steam so that
actual position can be compared to desired position.
 Signal Conversion
 Percentage % of Signal
0 25 50 75 100

15 100
Pneumatic Signal (PSIg)

12 75

% of Signal
Linear
9 50

6 25

3 0

4 8 12 16 20
Current Signal (mA)
 Pneumatic Relays
 Relay: A device that acts as a power amplifier. It
takes an electrical, pneumatic, or mechanical input
signal and produces an output of a large volume flow
of air or hydraulic fluid to the actuator. The relay can
be an internal component of the Positionar or a
separate valve accessory.
 Quick Exhaust Relay Signal to Actuator Vent

A Device that act as Actuator

Quick Exhaust
Relay
4 ~ 20 mA
Signal

safety device. In case of E/P

instrument air failure its

3 ~ 15 PSI 20 PSI

Positionar
operate and provide Air supply

shortcut to vent all Air supply

100 PSI

Feed Back
instrument air traps in Link
100 PSI

control valve chamber. Valve

Steam
 Pneumatic Relays
 Reverse Relay
A Device that invert pneumatic instrument
signal from 0% to 100% into pneumatic
instrument signal 100% to 0% for an other
system operations.

Reversing Relay
Input signal 3~ 15 PSI Output signal 15 ~ 3 PSI
 Pneumatic Relays
 Volume Booster Relay
A stand-alone relay is often referred to as a volume
booster or simply booster because it boosts, or
amplifies, the volume of air supplied to the actuator.
This device is used for a large size actuators. That
required air pressure more then instrument air
standard pressure(100 PSI).
Signal to Actuator Air Supply More
then 100 PSI

Volume
Actuator 4 ~ 20 mA
Booster Relay
Signal

E/P
3 ~ 15 PSI 20 PSI

Positionar
Air supply
100 PSI
Air supply
 Pneumatic Relays
 Lockup Relay
Lock-up system used to close air circuit to actuator
of control valve in case of plant instrument air failure.
Main valve will remain in position it occupied at time
of supply pressure failure. Signal to Actuator

Lockup Relay

Actuator

E/P
3 ~ 15 PSI 20 PSI

Positionar
Air supply
100 PSI
Air supply
100 PSI
Measuring & Control
DAY 17
SAO-08
By:
Muhammad Ashfaq Ch
Tehseen Ahmad
 Final Control Element
Most popular final control element is control valve.
Control valve: The control valve manipulates a
flowing fluid, such as gasses, 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.
Three Main Section
 Actuator
 Valve Body
 Hand Jack

Fail-Closed: A condition wherein the valve closure

member moves to a closed position when the
actuating energy source fails.
Fail-Open: A condition wherein the valve closure
member moves to an open position when the
actuating energy source fails.
Common parts of control valve
 Major Components of Control Valve

Travel
Indicator
ACTUATOR

CONTROL
VALVE

BONNET
VALVE BODY
ASSEMBLY

BODY
 Types of Actuator Action
Actuator: A pneumatic, Air Signal

hydraulic, or electrically
Direct Actuator Reverse Actuator
powered device that
supplies force and motion to
open or close a valve. Air Signal

 Direct Actuator: A
diaphragm actuator in which
the actuator stem extends Travel Valve
Steam
Travel Valve
Steam

with increasing diaphragm

pressure.
 Reverse Actuator: A
diaphragm actuator in which
the actuator stem retracts
with increasing diaphragm Reverse
pressure.
Direct
 Types of Actuator
 Diaphragm: A flexible, pressure responsive element
that transmits force to the diaphragm plate and
actuator stem.
 Diaphragm Actuator: A fluid powered device in
which the fluid acts upon a flexible component, the
diaphragm.
There are two types
 Direct Actuator
 Reveres Actuator
 Types of Actuator
 Piston: A movable pressure responsive element
that transmits force to the piston actuator stem.
 Piston Type Actuator: A fluid powered device in
which the fluid acts upon a movable piston to
provide motion to the actuator stem.
 Piston type actuators are classified as either
single-acting or double-acting, so that full power
can be developed in either direction, or as spring-
fail so that upon loss of supply power, the
actuator moves the valve in the required direction
of travel.
 Types of Actuator
Flapper: A movable pressure
responsive element that
transmits force to the flapper Moving

actuator stem. Pressure in Flapper

 Flapper Type Actuator: A Chamber

fluid powered device in which

the fluid acts upon a movable
Flapper to provide Angular
motion to the actuator stem.
 Flapper type actuators are
classified as only double-
acting, the actuator moves the
valve in the required direction Pressure in

of travel.
 Types of Actuator
Solenoid Valve: (SOV)
The solenoid valve is electro-magnetically
actuated. They are generally used to provide two
position (ON / OFF) or can be either energized to
open or energized to close
Motorized Valve: (MOV)
The electric Motor drive, to reduction gears and
output shaft or lever arm actuate Valve Plug.
These have been used where proportional
positioning of the final control element has been
required.
 Types of Valve Body Actions
Valve Body: The main pressure boundary of the valve that also
provides the pipe connecting ends, the fluid flow passage
way, and supports the seating surfaces and the valve closure
member.
Push-Down-to-Close or Direct Plug:
A globe-style valve construction in which the closure member
is located between the actuator and the seat ring, such that
extension of the actuator stem moves the closure member
toward the seat ring, finally closing the valve

Direct Plug
 Types of Valve Body Actions
Push-Down-to-Open Construction or Reverse Plug:
A globe-style valve construction in which the seat ring
is located between the actuator and the closure
member, so that extension of the actuator stem moves
the closure member from the seat ring, opening the
valve.

Reverse Plug
 Types of Valve Body Actions
 Single Seat: Single-seated valves, are usually employed when
tight shut-off is required. Single-seated valves usually have a
top guided construction. It also allows a somewhat higher
flow capacity than top and bottom guided valves for a given
orifice size.
 Double Seat: A double-seated value, is generally
top and bottom guided. Leakage figure
approaches 0.5% of the rated CV. It is nearly
impossible to close the two ports simultaneously
Advantage of double-seated construction lies in
the reduction of required actuator forces.
 Types of Valve Plugs
 Plug: A term frequently used to refer to the closure member.
 Seat: The area of contact between the closure member and
its mating surface that establishes valve shut-off.
 Many different types of plugs are used.
 Globe Valve: A valve with a linear motion closure member,
one or more ports, and a body distinguished by a globular
shaped cavity around the port region.
 Globe valves can be further classified as:
 Two-way single-ported;
 Two-way double-ported
 Types of Valve Plugs
 Cage: A part of a valve trim that surrounds the closure
member and can provide flow characterization and/or
a seating surface. It also provides stability, guiding,
balance, and alignment, and facilitates assembly of
other parts of the valve trim. The walls of the cage
contain openings that usually determine the flow
characteristic of the control valve. Various cage styles
are shown in figure
 Types of Valve Plugs
 Butterfly
Disk, Conventional: The symmetrical
flow-controlling member used in the
most common varieties of butterfly
rotary valves. High dynamic torques
normally limit conventional disks to 60
degrees maximum rotation in throttling
service.
Disk, Dynamically Designed: A
butterfly valve disk contoured to reduce
dynamic torque at large increments of
rotation, thereby making it suitable for
throttling service with up to 90 degrees
of disk rotation.
 Types of Valve Plugs
Ball, Full: The flow-controlling
member of rotary-shaft
control valves using a
complete sphere with a flow
passage through it. The flow
passage equals or matches
the pipe diameter.
 Types of Valve Plugs
Ball, Segmented: The flow–
controlling member of rotary
shaft control valves using a
partial sphere with a flow
passage through it.
Ball, V-notch: The most common
type of segmented ball control
valve. The V-notch ball includes
a polished or plated partial-
sphere surface that rotates
against the seal ring throughout
the travel range. The V-shaped
notch in the ball permits wide
rangeability and produces an
equal percentage flow
characteristic.
 Types of Valve Plugs
 Needle Plug

Direct Plug
 Types of Valve Plugs
Diaphragm type
using rubber of flexible plastic are
used in low pressure corrosive
service and for slurries they provide
high range ability good shutoff. Long
life and friendly maintenance valve,
A flexible disc or diaphragm used as
closing element
 Hand Jack
Manual Actuator or Hand Jack
Manual actuators or hand jacks are useful where
automatic control system under maintenance. They
are often used to actuate the valve and bypassed
control loop signal to control valves. for manual
control of the process during maintenance or
shutdown of the automatic system. They are
available in
 Top Mounted
 Side Mounted
 Special Valve
 Self Acting Pressure Control Valve
(PCV): In self Acting pressure control
valve, Actuator and valve body in one
compact unit providing installation
economy and long term reliability. The
outlet pressure directly actuate to
diaphragm mechanism and Pressure Signal
maintained set outlet pressure.
 No further instrumentation
required for control

Pressure In Pressure Out

 Special Valve
 Self Acting Temperature
Control Valve (TCV): In self
Acting Temperature control valve,
Actuator and sealed thermal
system in one compact unit
providing installation economy and
long term reliability. Available
either Direct-acting (valve close on
temperature rise) or Reverse-
acting (valve opens on
temperature rise).
 No further instrumentation required
for control
 Special Valve
 Self Acting Flow Control
Valve (FCV): In self Acting
Flow control valve, Actuator and
Valve body in one compact unit.
Variable area meter measured
flow rate and provide control
signal to FCV for maintained
Flow rate.
 This type of arrangement is
commonly used to controlled air
flow rate for Bubbler type level
measurement
 Special Valve
 Pressure Safety Valve (PSV)
“A pressure relief valve is a safety
device designed to prevent
internal fluid pressure from rising
above pre determined maximum
pressure in a pressure vessel
exposed to emergency or
abnormal condition.”
Measuring & Control
DAY 18
SAO-08
By:
Muhammad Ashfaq Ch
Tehseen Ahmad
 Concept of Control Loop

1. Sensor / 1

Transmitters

2. Controller 3

3. Final Control
Element
22
 Control Loop Block

Control Sensor
Manipulated Variable
Valve
Control Variable Process Process Variable
/ Tx
Measured Variable

Measurment
Action

Out Put Controller PV In Put

SP
 Terminology
 Control Variable
The Variable that Must be Maintained or Controlled at
Some Desire Value.
 Manipulated Variable (MV)
The Variable used to Maintain the Controlled Variable
at its Set Point.
 Process Variable (PV)
A Quantity that can be Measured and can change in
an Industrial Process is called a Process Variable for
Example Pressure, Temperature, Level, Flow, etc.
 Measured Variable
Process after Measurement is called Measured
Variable
 Terminology
 In put (I/P)
The thing which enters in a system is called input to
the system.
 Out put (O/P)
The thing which come out or obtained from a system
is called output of the system.
 Set Point (SP)
The Desired Value of a Process Variable.
 Error
Error is Defined as the Difference Between the Set
Point and the Measured Value of a Process Variable.
 Control point Terminology
The value at which the process variable returns to
steady state.
 Offset
The amount of difference between the control point of
a process variable and its set point.
 Steady State
The condition of a process variable when it is not
changing.
 Process Disturbances
Conditions that can cause a process variable to
change away from its set point are called process
disturbances.
 Terminology
 Damping
To control the sensitivity of process variable is called
damping
 Hunting
An abnormal and continual cycling of the process
variable caused by a control system unsuccessful
efforts to achieve the control.
 Dead Time / Dead Zone
The term "dead zone" refers to the amount of change
that can occur in a process without triggering a control
action.
 Terminology
 Manual Control
A form of control that is performed by an operator
 Automatic control
A form of control that is performed automatically by
process control instrumentation without human
intervention.
 Auto/ Manual
A selector switch of a controller to put control loop on
automatic mode or manual mode
 Terminology
 Cascade
control in which two or more control loops are
arranged so that the output of one controlling element
(Master Controller) adjust the set point of another
controlling element (Sleeve controller).
 Local / Remote
A Special selector switch of a Slave controller to put
control loop on Cascade mode (set point from other
controller output) or manual set point mode
 Open Loop
 It is a system of control that provides information
necessary for control without comparing a measured
value of a process variable to the desired value of the
process variable.

Process
Display only

Process Manually
control
 Close Loop
 A combination of control units in which the process
variable is measured and compared with the desired
value, or set point. If there is a difference, a corrective
signal is sent to the final control element to bring the
controlled variable to the desired value.
1. Measurement 1
2. Decision
3. Action

2
 Feedback Control
 A method of control in which a measured value of
process variable is compared with the desired value of
the process variable and necessary corrective action
is taken.
 Feed forward control
 A method of control in which the value of a disturbance is
measured and action is taken to prevent the disturbance from
changing the value of process variable. It is control design to
prevent errors from occurring in a process variable.
Concept of Auto / Manual Station
When operator, with selector switch to
put control loop on automatic mode that
controller is performed automatically or
controller on manual mode process
control by an operator.
 Field / Plant Rack room Control room

Alarm Annunciatot
0~10 V 0~1 Binary
Pressure Alarm
Transmitter Card

Process 4~20mA I/V 0~10 V

Converter
Input Card

0~10 V
Indicator

0~10 V

0~10 V
Recorder

0~10 V 0~10 V
Controller
Card Control
4~20mA Station
V/I
3~15 PSI
Converter
Output Card 0~10 V

Process

A Control Loop
 Block Diagram of FFC Control System

FIELD RACK ROOM CONT ROOM

Distributor Recorder

REC
Sensor Tx JB I/O Barrier

Controller

Cont

CV E/P JB O/P Barrier Distributor