Basic Components of

Control
 Three Basic Operations of Control
System
 Measurement (M)
 Decision (D)
 Action (A)
 Sensors and Transmitter
 The purpose of the sensor/transmitter
combination: to generate a signal that is
related to the process variable
 Do you know these sensors?
 Potentiometer
 Linear Variable Differensial Transformer (LVDT)
 STRAIN GAUGE
 LOAD CELL
 Bourden tube
 Orifice meter
 Ultrasonic sensor
 Thermocouple
 RTD
 Thermistor
 Proximity
 Limit Switch
Most commonly measured
process conditions:
temperature, level, pressure,
flow rate, pH.
Other variables include
composition, moisture, specific
gravity, viscosity, dissolved
oxygen.
 Chemical sensors
 A chemical sensor is a device that transforms chemical
information, ranging from the concentration of a specific
sample component to total composition analysis, into an
analytically useful signal.
 The chemical information, mentioned above, may
originate from a chemical reaction of the analyte or from
a physical property of the system investigated.
 Chemical sensors contain two basic functional units: a
receptor part and a transducer part.
 Some sensors may include a separator which is, for
example, a membrane.
 Cont’d
 In the receptor part of a sensor the
chemical information is transformed into a
form of energy which may be measured by
the transducer.
 The transducer part is a device capable of
transforming the energy carrying the
chemical information about the sample
into a useful analytical signal.
 Cont’d
 The receptor part of chemical sensors may be based upon
various principles:
 - physical, where no chemical reaction takes place. Typical
examples are those based upon measurement of absorbance,
refractive index, conductivity, temperature or mass change.
 - chemical, in which a chemical reaction with participation of
the analyte gives rise to the analytical signal.
 - biochemical, in which a biochemical process is the source of
the analytical signal. Typical examples are microbial
potentiometric sensors or immunosensors. They may be
regarded as a subgroup of the chemical ones. Such sensors
are called biosensors.
 CLASSIFICATION OF
CHEMICALSENSORS
 Chemical sensors may be classified according to the
operating principle of the transducer:
 Optical
 Electrochemical
 Electrical
 Mass sensitive
 Magnetic
 Thermometric
 Other physical properties as for example X-, β- or Г-
radiation may form the basis for a chemical sensor in case
they are used for determination of chemical compostion.
 Optical devices
 transform changes of optical phenomena, which are the result of an interaction of
the analyte with the receptor part.
 This group may be further subdivided according to the type of optical properties which
have been applied in chemical sensors:
 a) absorbance, measured in a transparent medium, caused by the absorptivity of the
analyte itself or by a reaction with some suitable indicator.
 b) reflectance is measured in non-transparent media, usually using an immobilized
indicator.
 c) luminescence, based on the measurement of the intensity of light emitted by a
chemical reaction in the receptor system.
 d) fluorescence, measured as the positive emission effect caused by irradiation. Also,
selective quenching of fluorescence may be the basis of such devices.
 e) refractive index, measured as the result of a change in solution composition. This
may include also a surface plasmon resonance effect.
 f) optothermal effect, based on a measurement of the thermal effect caused by light
absorption.
 g) light scattering, based on effects caused by particles of definite size present in the
sample.
 Electrochemical devices
 transform the effect of the electrochemical interaction analyte - electrode into a
useful signal.
 An electrochemical sensor is a device that converts chemical
information into an electrical signal. It can detect and measure the
concentration of specific substances in a mixture.
 The following subgroups may be distinguished:
 a) voltammetric sensors, including amperometric devices, in which current
is measured in the d.c. or a.c. mode. This subgroup may include sensors
based on chemically inert electrodes, chemically active electrodes and
modified electrodes.
 b) potentiometric sensors, in which the potential of the indicator electrode
is measured against a reference electrode.
 c) chemically sensitized field effect transistor (CHEMFET) in which the
effect of the interaction between the analyte and the active coating is
transformed into a change of the source-drain current.
 d) potentiometric solid electrolyte gas sensors,
 Electrical devices
 no electrochemical processes take place, but the signal
arises from the change of electrical properties caused by
the interaction of the analyte.
 a) metal oxide semiconductor sensors used principally as gas
phase detectors, based on reversible redox (reduction-
oxidation) processes of analyte gas components.
 b) organic semiconductor sensors, based on the formation of
charge transfer complexes, which modify the charge carrier
density.
 c) electrolytic conductivity sensors.
 d) electric permittivity sensors.
 Mass sensitive devices
 transform the mass change at a specially modified
surface into a change of a property of the support
material. The mass change is caused by accumulation of
the analyte.
 a) piezoelectric devices used mainly in gaseous phase, but also
in solutions, are based on the measurement the frequency
change of the quartz oscillator plate caused by adsorption of a
mass of the analyte at the oscillator.
 b) surface acoustic wave devices depend on the modification of
the propagation velocity of a generated acoustical wave affected
by the deposition of a definite mass of the analyte.
 Magnetic devices
 based on the change of paramagnetic
properties of a gas being analysed.
 These are represented by certain types of
oxygen monitors.
 Thermometric devices
 based on the measurement of the heat effects of a
specific chemical reaction or adsorption which involve
the analyte.
 In this group the heat effects may be measured in
various ways, for example in the so called catalytic
sensors the heat of a combustion reaction or an
enzymatic reaction is measured by use of a thermistor.
 The devices based on measuring optothermal effects (If)
can alternatively be included in this group.
 Other classification
 Sensors have also been classified according to the
application to detect or determine a given analyte.
 Examples are sensors for pH, for metal ions or for determining
oxygen or other gases.
 Another basis for the classification of chemical sensors
may be according to the mode of application,
 for example sensors for process monitoring
 Transmitter
 To convert the output from the sensor to a
signal strong enough to be transmitted to a
controller or any other receiving device
 There are two transmitter that is most
used:
 Pneumatic transmitter

 Electrical transmitter
 Three important terms related to
the sensor/transmitter combination
 Range: low and high values of the process
variable
 Span: The difference between the upper range
and the lower range
 Zero: the low value of the range

 Example: pressure sensor/transmitter has been

calibrated to measure a process pressure between
the values of 20 psig and 50 psig.
  range = 20 – 50 psig. Span=30psig. Zero=20 psig
Transfer function form
TO(s)
PV(s)
H(s)

 Transfer function (first order lag):

TO s  KT
H s   
PV s   T s  1
 Where: K T transmitter gain
  T transmitter time constant
Example
 pressure sensor/transmitter has been calibrated
to measure a process presure between the
values of 0 psig and 200 psig.the output of this
sensor/transmitter are 4 – 20 mA

KT 
20  4 mA

16 mA
0.08mA/psig
200  0psig 200 psig
or in percent transmitter output (%TO)

KT 

100  0 %TO
0.5%TO/psig
200 - 0psig
lanjut
 Jika transmitter mempunyai time constant
3 s maka fungsi alih transmitter adalah

TO s  KT 0.5 %TO
H s    
PV s   T s  1 3s  1 psig
Exercise
 For each of the following cases, calculate the gain
in percent transmitter output per variable unit,
write the transfer function and draw the block
diagram
 A. a temperature transmitter with a range of 100 to
1500C and a time constant of 1.2 min
 B. a temperature transmitter with a range of 100 to
350°F and a time constant of 0.5 min.
 C. a pressure transmitter with a range of 0 to
50psig and a time constant of 0.05 min
 D. a level transmitter with a range of 0 to 8 ft and a
negligible time constant
VALVES
 What are VALVES?
 Mechanical devices designed to
direct, stop, mix or regulate the
flow, pressure or temperature of
a process fluid.
 Control Valve Action
 Depend on the position of valve when the energy supply
fails:
 1. fail-closed (FC) valve
Valve requires energy to open air-to-open (AO)
valve
 2. fail-open (FO) valve
Valve requires energy to close air-to-close (AC)
valve
Air To Close Valve

Δ P FLOW =P1-P2
Δ P SHUTOFF =P1-PLOAD
1. USUALLY Δ P SHUTOFF > Δ P
FLOW
2. Methods to increase Δ P SHUTOFF
1. Increase PLOAD
2. Increase ADiaphragm
3. Reduce FSpring
4. Reduce ζ Packing
ΣFup = ΣFdown
P1 * APort+ FSpring+
ζPacking=PLOAD* ADiaphragm+
P2 * APlug

Note: Inlet Pressure tends to push

open plug
Air To Open Valve

Δ P FLOW =P1-P2
Δ P SHUTOFF =P1-PLOAD
1. USUALLY Δ P SHUTOFF > Δ P
FLOW
2. Methods to increase Δ P SHUTOFF
1. Decrease PLOAD
2. Increase ADiaphragm
3. Increase FSpring
4. Reduce ζ Packing
ΣFup = ΣFdown
P1 * APort+PLOAD* ADiaphragm +
ζPacking= FSpring +P2 * APlug

Note: Inlet Pressure tends to push

open plug
Transfer function form
M(s),%CO F(s),gpm (gallons per minute)
Gv(s)

 Transfer function (first order lag):

KV
GV s  
 V s 1
 Where: KV  valve gain (gpm/%CO)
  V valve time constant (s)
Gain of valve with linear
characteristics
f max gpm
KV  ,
100 %CO
Where fmax is the flow through the valve when it is fully opened

pv
f Cv
Gf
dengan
f liquid flow (gpm)
Δpv pressure drop accross the valve (psi)
G f specific gravity of liquid at flowing conditions liquid density
Cv the flow of water (gallons per minute/gpm) that flows through a valve
at a pressure drop of 1 psi accross the valve
Contoh
 Sebuah valve mempunyai kapasitas 110
gpm/(psi) ketika terbuka penuh. Besar
tekanan yang melalui valve adalah 10 psi.
 A. Hitung laju alir larutan dengan densitas
0.8 g/cm3
 B. Buat fungsi alih valve tsb jika valve
mempunyai time constant 2 s
Jawab
Cv 110 gpm/psi
pv 10 psi
G f 0.8g/cm 3
10
f 110 389 gpm
0.8
f max 389 gpm
KV   3.89
100 100 %CO

KV 3.89 gpm
GV s   
 V s  1 2s  1 %CO
Rumus fungsi alih valve
yang lain
Kapasitas steam maks kg/s
GV s  
 V s 1 %CO
 Contoh
 Valve mempunyai kapasitas steam maks
1.6 kg/s dan time constant 3 s

1.6 kg/s
GV s  
3s  1 %CO
Parts of a 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
Valve Types
 BallValve
 Butterfly Valve
 Gate Valve
 Globe Valve
 Check Valve
 Ball Valve
Sphere with a port in a housing, rotate to expose
channel.
 Applications: Flow control, pressure control,
shutoff, corrosive fluids, liquids, gases, high temp.
 Advantages – low pressure drop, low leakage
(kebocoran rendah), small, rapid opening
 Disadvantages – seat can wear if used for
throttling, quick open may cause hammer
Ball Valve
 Gate Valve
Sliding disk, perpendicular to flow
Applications: Stop valves, (not throttling), high
pressure and temp, not for slurries, viscous
fluids for fully open or fully closed service
Advantages – low pressure drop when fully
open, tight seal when closed, free of
contamination buildup
Disadvantages – vibration when partially open,
slow response and large actuating force
Gate Valve
 Butterfly Valve
rotating disk on a shaft, in a housing
can be used for isolating or regulating flow
Application: for flow regulation in large pipe
diameters
Low pressure, large diameter lines where
leakage is unimportant
Advantages – low pressure drop, small and light
weight
Disadvantages – high leakage, high actuation
forces so limited to low pressures
Butterfly Valve
 Check Valves
allows flow in only one direction
Swing valve similar to butterfly except
hinged along one edge rather than rotate
about the diameter, used primarily for check
valves.
Check valve
 Globe Valve
three types (globe, angle and Y), disc or plug
moved perpendicular to flow and closes on a ring
seat
Throttling, general purpose flow control valve
Advantages – faster than gate, seat less wear and
tear, high pressure drop for pressure control
Disadvantage high pressure drop, require
considerable power to operate (gears and levers),
heavy
Globe Valve
Valve Symbols
Butterfly Valve

Ball Valve

Gate Valve

Globe Valve
 ACTUATORS
A device mounted on a valve that in response to a

signal, automatically moves the valve to the required

position using an outside power source. The addition

of an actuator to a throttling valve is called a

CONTROL VALVE
 ACTUATORS

Pneumatic Electronic motor Electro hydraulic

Diaphragm Piston
PNEUMATIC ACTUATORS

Air is relatively inexpensive, 90% of the

Industries employ these actuators.

HYDRAULIC ACTUATORS

Exceptional stiffness & high thrust’ are

required, Fast stroking speeds.
Hydraulic fluid above and below a piston to position
the valve.
LINEAR ACTUATOR
ROTARY ACTUATOR
ELECTROHYDRAULIC ACTUATOR

Self contained hydraulic system, electrical

Signal feeds to an internal pumps, which uses
hydraulic fluid from a reservoir to feed hydraulic fluid above or below the
piston.

Pros – Exceptionally stiff because of the incompressibility of liquids.

Cons – Expensive and Bulky

 POSITIONERS
A device attached to an actuator that receives

An electronic or pneumatic signals from the controller

And compares this signal to the actuator’s position.

3-way positioners

Send and exhaust air to only one side of a

Single acting actuator that is opposed by a range
Spring.

4-way positioners

Send and exhaust air to both sides of an

actuator which is required for double acting
actuators.
 Reasons To use Positioners
• Increase control system resolution
i.e)fine resolution.
• Allow use of characteristic cams.
• Minimize packing friction effects.
• Allow Split Ranging.
• Overcome seating friction in rotary valves.
• Facilitate operation when the higher number in the
bench-set range is greater than 1ksc
 Reasons To use Positioners

• Permit use of piston actuators.

• Allow distance between controller and
control valve using the advantage of
4-20ma signal.
 Tugas kelompok
 Cari 1 contoh dan aplikasinya:
 Optical: kel 1
 Electrochemical: kel 2
 Electrical: kel 3
 Mass sensitive: kel 4
 Thermometric: kel 5
 Ball Valve: kel 6
 Butterfly Valve:kel 7
 Gate Valve: kel 8
 Globe Valve: kel 9
 Check Valve:kel 10