PROCESS CONTROL

The process may be controlled by measuring a variable representing the

desired state of the product and automatically adjusting one of the other
variables of the process. In process control, the basic objective is to
regulate the value of some quantity.
Automatic control is the maintenance of a desired value of a quantity or condition
by measuring the existing value, comparing it to a desired value, and employing the
difference to initiate action for reducing this difference. Thus automatic control
requires a closed loop of action and reaction operating without human aid
Actuator
Convert the industrial standard signal to action such as valve opening,
power level, displacement, and etc.
Standard instrumentation signal levels and signal conversion transmitters
are used.
Types of actuator
Pneumatic: simple, low cost, fast, low torque, hysteresis
Electric: motor and gear box, high torque, slow
Hydraulic: high torque, fast, expensive
Valves
a device for controlling the passage of fluid through a pipe or duct, especially an
automatic device allowing movement in one direction only
CONTROL VALVES
A Control Valve is a power-operated device used to modify the fluid flow rate in a
process system.
Control valves are valves used to control conditions such as flow, pressure,
temperature, and liquid level by fully or partially opening or closing in response to
signals received from controllers that compare a "setpoint" to a "process variable"
whose value is provided by sensors that monitor changes in such conditions.[1]
The opening or closing of control valves is usually done automatically by electrical,
hydraulic or pneumatic actuators. Positioners are used to control the opening or
closing of the actuator based on electric, or pneumatic signals. These control
signals, traditionally based on 3-15psi (0.2-1.0bar), more common now are 4-20mA
signals for industry
There are two basic types of control valves
a) Rotary motion valves having ball, butterfly or plug type closures.

b) Linear motion valves having globe, diaphragm or pinch type closures.

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TYPE OF VALVE
Ball Valve
Butterfly Valve
Gate Valve
Globe Valve
Parts of a Valve
1. Closure member: part of the valve that closes flow (disk, ball, gate,
etc.).
2. Actuator: means of operating the valve hand, gear, chain wheel,
motor, solenoid, pressure and flow of the media, air pressure.
3. End fitting: must be specified when buying the valve - butt weld end,
compression flange, pipe thread, quick disconnect
4. Material: closure member, housing, seat stainless steel
5. Packing/seals: seals stem, replaced
6. Seat: where the closure members seals against the valve housing

BALL VALVE

BALL VALVE WORKING

ball valve consisting of a spherical ball located between two
sealing rings in a simple body form. The ball has a hole allowing fluid to
pass
through. When aligned with the pipe ends, this gives either full bore or
nearly
full bore flow with very little pressure drop. Rotating the ball through
90
opens and closes the flow passage. Ball valves designed specifically for
control
purposes will have characterized balls or seats, to give a predictable
flow
pattern.
Ball valves are an economic means of providing control with tight shutoff for
many fluids including steam at temperatures up to 250C (38 bar g,
saturated
steam). Above this temperature, special seat materials or metal-tometal
seatings are necessary, which can be expensive. Ball valves are easily
actuated
and often used for remote isolation and control. For critical control
applications, segmented balls and balls with specially shaped holes are
available to provide different flow characteristics

BUTTERFLY VALVE

butterfly valve, which consists of a disc

rotating in trunnion bearings. In the open position the disc is parallel to
the pipe wall,
allowing full flow through the valve. In the closed position it is rotated
against a seat,
and perpendicular to the pipe wall. Traditionally, butterfly valves were
limited to low
pressures and temperatures, due to the inherent limitations of the soft
seats used.
Currently, valves with higher temperature seats or high quality and
specially
machined metal-to-metal seats are available to overcome these
drawbacks. Standard
butterfly valves
particularly in larger

are

now

used

in

simple

control

applications,

sizes and where limited turndown is required.

A fluid flowing through a butterfly valve creates a low pressure drop, in
that the valve
presents little resistance to flow when open. In general however, their
differential
pressure limits are lower than those for globe valves. Ball valves are
similar except
that, due to their different sealing arrangements, they can operate
against higher
differential pressures than equivalent butterfly valves.
GATE VALVE

A Gate Valve, or Sluice Valve, as it is sometimes known, is a valve that

opens by lifting a round or rectangular gate/wedge out of the path of the
fluid. The distinct feature of a gate valve is the sealing surfaces between the
gate and seats are planar. The gate faces can form a wedge shape or they
can be parallel. Gate valves are sometimes used for regulating flow, but
many are not suited for that purpose, having been designed to be fully
opened or closed. When fully open, the typical gate valve has no obstruction
in the flow path, resulting in very low friction loss.
GLOBE VALVE

Globe valves are named for their spherical body shape. The two halves of the valve
body are separated by an internal baffle which has an opening forming a seat onto
which a movable disc can be screwed in to close (or shut) the valve. In globe valves,
the disc is connected to a stem which is operated by screw action. When a globe
valve is manually operated, the stem is turned by a handwheel. Although globe
valves in the past had the spherical bodies which gave them their name, many
modern globe valves do not have much of a spherical shape, but the term globe
valve is still often used for valves that have such an internal mechanism. In
plumbing, valves with such a mechanism are also often called stop valves since
they don't have the global appearance, but the term stop valve may refer to valves
which are used to stop flow even when they have other mechanisms or designs.
Globe valves are named for their spherical body shape. The two halves of the valve
body are separated by an internal baffle which has an opening forming a seat onto
which a movable disc can be screwed in to close (or shut) the valve. In globe valves,
the disc is connected to a stem which is operated by screw action. When a globe
valve is manually operated, the stem is turned by a handwheel. Although globe
valves in the past had the spherical bodies which gave them their name, many
modern globe valves do not have much of a spherical shape, but the term globe
valve is still often used for valves that have such an internal mechanism. In
plumbing, valves with such a mechanism are also often called stop valves since
they don't have the global appearance, but the term stop valve may refer to valves
which are used to stop flow even when they have other mechanisms or designs.
Controlled Variables
Controlled variables are variables that we want to maintain at constant or specified
values (T, P, flow rate, level, etc.).
Manipulated Variables

Manipulated variables are variables that we intentionally change to maintain our

controlled variable at a constant value. We often manipulate the values by opening
or closing a valve.
Measured Variables
Measured variables are variables that we measure with a meter (often often the
controlled variable or a variable that we use to calculate the controller variable).

Control valve characteristics