A Review of Process Instrumentation, Control Valves, and the Control Loop

CM4120 Unit Operations Lab January 2011

Outline
Process Instrumentation Review A look at Regulatory Control Valves What is a Control Loop? PID Controllers and terminology

Temperature Measurement
Thermocouples
low cost sensor needs transmitter/readout -440 to 5000F, typically 1 to 2F accuracy wide temperature range for various types rugged, but degrades over time many modern transmitters can handle T/C or RTD
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Temperature Measurement
RTDs
-300 to 1150F, 0.1F accuracy or better more fragile, expensive than T/C very stable over time wide temperature range also needs readout/transmitter

Pressure Measurement
Pressure Transmitters
available in gage pressure, absolute pressure and differential pressure typically 0.075% range accuracy 50:1 turndown same transmitter and sensor body as in dP flow measurement and dP level

Flow Measurement
Differential Pressure Orifice Meter
well-characterized and predictable causes permanent pressure (energy) loss in piping system, typically 8 ft. head loss (3 to 4 psi loss) 5:1 rangeability requires straight run of 20 pipe diameters upstream, 5 downstream suitable for liquid, gas, and steam accuracy is 1 to 2% of upper range
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Flow Measurement
Turbine Flow Meter
accuracy is 0.25% of rate good for clean liquids, gases 5 to 10 pipe diameters upstream/downstream 10:1 turndown 3 to 5 psig pressure drop

Flow Measurement
Magnetic Flow Meter (Mag Meter)
0.4 to 40 ft/s, bidirectional accurate to 0.5% of rate fluid must meet minimum electrical conductivity head losses are insignificant good for liquids and slurries upstream/downstream piping does not effect reading linear over a 10:1 turndown
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Flow Measurement Vortex Flow Meter

suitable for liquids, steam, and gases must meet min. velocity spec 0.5 to 20 ft/sec range for liquid 5 to 250 ft/sec for gases non-clogging design not suitable if cavitation is a problem accuracy is % of rate up to 5 psig head loss linear over flow ranges of 20:1
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Flow Measurement
Coriolis Effect Mass Flow Meter
used for steam, liquids, gases measure mass flow, density, temperature, volumetric flow expensive, but 0.2% of rate accuracy very stable over time 100:1 turndown negligible to up to 15 psig head loss
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Level Measurement
Non-Contacting Radar Level
suitable for liquids and solids foaming, turbulence, vessel walls and internals can effect signal if not installed correctly can use stilling leg if turbulence is extreme typically 0.1 inch accuracy

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Level Measurement
Contacting dP Level
suitable for liquids only foaming and turbulence will effect signal can use stilling leg if turbulence is extreme typically 0.05% range accuracy 100:1 turndown uses same dP transmitter as in dP flow measurement

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Regulatory Control Valve

Actuator
(F.O. or F.C.?)

Trim set desirable to have flow linearly proportional to valve position for good control

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Valve Trim Inherent Characteristics

Quick Opening safety by-pass type Large flow response when valve starts opening is more important than linear response Equal Percentage ~ 80% of all control valves provides linear response to valve position Linear used when majority of system pressure drop is due to valve position
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Flow Coefficient vs. Valve Position for each Valve Characteristic

By definition: for Cv = 1, 1 gpm flow w/ 1 psi pressure drop across valve

f(x)

QO 0.5 Linear =% 0 0 20 40 60 80 Stem Position (% Open) 100

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Installed Characteristic
Size the valve trim, then select valve characteristic w/ the most linear response:
Installed Flow Rate (GPM) 200 150 100 50 0 0 20 40 60 80 Stem Position (% Open) 100 =% Valve Linear Valve

use Equal Percent Characteristic valve to achieve a linear Installed Characteristic

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Typical Control Loop

All elements of a loop have same loop number

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PID Controllers

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Review of Controller Terminology

Process Variable (PV) = Measured variable of interest, in EU Setpoint (SP) = Desired value of the PV, in EU Output (OP) = Controller output, 0-100% Error = Difference between Setpoint and PV

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Relating this to our Control Loop:

Setpoint

Process Variable Output

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Controller Terminology
PID control Dynamic equation that is used to match the controllers response to a measured disturbance. Goal is to minimize disturbance and return to setpoint Equation is tuned to match process response using up to 3 tuning constants

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Controller Terminology
Tuning Constants: Proportional term Adjusts output proportional to the error multiplied by Gain Integral term Added to output based on error existing over time, Reset Derivative term Additional adjustment to output based on rate of change of error, Rate

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Controller Terminology
Controller Modes of Operation: Auto mode Output of controller is set by PID algorithm based on features enabled and tuning parameters Manual mode Output is controlled by an operator (i.e. not in control) Cascade mode Output is controlled by PID but setpoint comes from the output of a primary or master controller

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References
Miller, Richard W., Flow Measurement Engineering Handbook, 3rd Ed., McGraw-Hill, New York, 1996. Riggs, James B., Chemical Process Control, 2nd Ed., Ferret Publishing, Lubbock, TX, 2001. Taylor Instrument Division, The Measurement of Process Variables, no date. www.emersonprocess.com/rosemount/, Rosemount, Inc., Oct. 2006. www.emersonprocess.com/micromotion/, Micro Motion, Inc., Oct. 2006. www.ametekusg.com/, Ametek, Inc. Oct. 2006.
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