PLC Architecture

Programming
Interface
PLC Cabinet

Power
Processor
Supply

Data Highway

I/O Modules

Input Output
Devices Devices

Fieldbus Technology :
 Based upon smart valves
 smart sensors and controllers installed in the field
 Uses data highway
 Can mix different sources
 Less expensive installations

Fieldbus Architecture

Data Storage Plant Optimization

High Speed Ethernet

PLCs

Local Local
Area
Network
................. Area
Network

H1 Fieldbus H1 Fieldbus

Smart Smart Control Smart Smart Control

Sensors Valves and Sensors Valves and
Controllers Controllers

H1 Fieldbus Network H1 Fieldbus Network

Actuator System :
 Control Valve
 I/P converter
 Instrument air system

Typical Globe Control Valve

Cross-section of a Globe Valve

Types of Globe Valves

 Quick Opening- used for safety by-pass applications
 Equal Percentage- used for about 90% of control valve applications
 Linear- used when a relatively constant pressure drop
Inherent Valve Characteristics
1

QO
0.5
f(x)

Linear

=%

0
0 50 100
Stem Position (% Open)

Use of the Valve Flow Equation

Given: water as the fluid; P  16 psig; Cv  5
Determine the flow rate through this control
valve. Using Equation 2.3.3,
FV  KCv p / s.g .  (1)(5) 16 /1  20 gpm
Typical Flow System
C.W.

FT

Pressure Drop vs. Flow Rate

25
Pressure Drop (psi)

20 Pump Head

15 Valve P
10
5 Line Losses
0
0 100 200
Flow Rate (GPM)
 Installed Flow Characteristic

200 Linear Valve

Installed Flow Rate

150
(GPM)

100 =% Valve
50

0
20 40 60 80 0 100
Stem Position (% Open)
Slope of Installed Characteristic

7
Slope of the Installed
Flow Characteristic

6 Linear
5 Valve
4
=% Valve
3
2
1
0
0 20 40 60 80 100
Stem Position (% Open)

Effect of Linearity in the Installed Valve Characteristics

Highly nonlinear installed characteristics can lead to unstable flow control

Flow System with Relatively Constant Valve Pressure Drop

FT 30 ft

Pressure Drop vs. Flow Rate

15
Hydrostatic Head
Pressure Drop (psi)

10 Valve P

5
Line Losses
0
0 100 200 300 400 500 600
Flow Rate (GPM)
Installed Valve Characteristics

600
Installed Flow Rate

500
400
Linear
(GPM)

300
200
100 =%
0
0 20 40 60 80 100
Stem Position (% Open)

Analysis of These Examples

 Note the linear installed valve characteristics over a wide range of stem positions.
 If the ratio of pressure drop across the control valve for the lowest flow rate to the
value for the highest flow rate is greater than 5
Control Valve Design Procedure
 Evaluate Cv at the maximum and minimum
 Determine which valves can effectively
 Choose the smallest valve
Additional Information Required to Size a Control Valve
 CV versus % open for different valve sizes
 Available pressure drop across the valve versus flow rate for each valve
Valve Sizing Example
Size a control valve for max 150 GPM of water and min of 50 GPM
Determine CV at Max and Min FV
• Use the valve flow equation (Equation 2.3.3) to calculate Cv
• For ΔP, use pressure drop versus flow rate (e.g., Table on page 82)

Fm
Cv ( x) 
K P / 
150 50
Cvmax   28.9; Cvmin   9.1
27 /1 30 /1

Valve Position for Max and Min Flows for Different Sized Valves
Max flow Min flow
1-inch valve not large enough 75%
1.5-inch valve not large enough 68%
2-inch valve 67% 45%
3-inch valve 55% 30%
4-inch valve 47% 22%
Analysis of Results

 2-inch valve appears to be best overall choice: least expensive capital and it can
provide up to a 50% increase in throughput
 .3-inch and 4-inch valve will work, but not recommended because they will cost
more to purchase. The 2-inch valve will provide more than enough extra capacity.

Valve Deadband
• It is the maximum change in instrument air pressure to a valve that does not cause
a change in the flow rate through the valve.
• Deadband determines the degree of precision that a control valve or flow controller
can provide.
• Deadband is primarily affected by the friction between the valve stem and the
packing.

For Large Diameter Lines (>6”), Use a Butterfly Valve

Valve Actuator Selection

• Choose an air-to-open for applications for which it is desired to have the valve fail
closed.

• Choose an air-to-close for applications for which it is desired to have the valve fail
open.

Cross-section of a Globe Valve