Signal Transmissions

Faculty of Chemical Engineering, Universiti Teknologi MARA Malaysia

Specially prepared for the following courses:

Process Control & Instrumentation
Chemical Process Control

Signal Transmissions

Signal Transmissions
Signals
1.
2.
3.

Current:
Voltage:
Pneumatic:

0/4-20 mA
1-5 V
3-15 psi

Transmission
A transmitter (e.g. flow transmitter) transmits between 4 to 20 mA current to a controller. The controller, upon
computation, will transmit an output between 4 to 20 mA to an I/P. This I/P will produce an output between 3 to
15 psi which equivalent to the current received from the controller. The output of an I/P will be translated into
equivalent stem position between 0 to 1 of a control valve.

4-20 mA

FT

FC

4-20 mA

I/P
3-15 psi (ATO)
15-3 psi (ATC)

1 = valve fully open

0 = valve fully closed

Abdul Aziz Ishak, Universiti Teknologi MARA (2011)

Signal Transmissions

Application of signal transmission

Wastewater treatment system

0
100%
Flowrate

4
20 mA
supply tank

4
20 mA
4
20 mA
1
5 V

Abdul Aziz Ishak, Universiti Teknologi MARA (2011)

Signal Transmissions

Application of signal transmission

SCADA system
R/L

FC
101

I/P
101
PROCESS
CONTROL
LOOP 102

FT
101
TY
101

PROCESS
CONTROL
LOOP 101

LT
102

TT
102

DAQ card
LC
102

TC
102

TR
102

DAQ card

PUMP SWITCH

PANEL
BOX

Abdul Aziz Ishak, Universiti Teknologi MARA (2011)

Signal Transmissions

Application of signal transmission

Computer controlled system
I/P
101
PROCESS
CONTROL
LOOP 102

FT
101
TY
101

PROCESS
CONTROL
LOOP 101

LT
102

TT
102

Signals based on card I/O

DAQ PCI card

Abdul Aziz Ishak, Universiti Teknologi MARA (2011)

Signal Transmissions

Signal Converters

Image

Device

Signal A

to Signal B

into B

I/P

Current

Pneumatic

0/4 20 mA

3 15 psi

V to I

Voltage

Current

15V
0 10 V
-10 to 10 V

4 20 mA

Shunt
resistor

Current

Voltage

4 20 mA

15V

Abdul Aziz Ishak, Universiti Teknologi MARA (2011)

Signal Transmissions

Signal Conversions
Signal to signal conversion: Linear relationship.
Example 1(a): Signal conversion between controller output, I/P output and stem position.
Table representation
Linearized scale, %

CO (mA)

I/P (ATO, psi)

I/P (ATC, psi)

Control Valve
Opening

Stem position, x

15

Closed

25

12

0.25

50

12

0.5

75

16

12

0.75

100

20

15

Abdul Aziz Ishak, Universiti Teknologi MARA (2011)

Open

Signal Transmissions

Signal Conversions
Example 1(b): Signal conversion between controller output, I/P output and stem position.
Graphical representation

Mathematical representation

20

y = mx + c

16
I
12
mA
8
4
Linearized scale, % 0
stem position, x 0

25

50

75

100

0.5

ATO, psi 3

15

ATC, psi 15

Abdul Aziz Ishak, Universiti Teknologi MARA (2011)

Signal Transmissions

Signal Conversions
Example 2:
A flow meter has been calibrated between 0 to 25 LPM
for a 4 to 20 mA signal output. Calculate the signal
transmitted to the controller if the flow rate is 15 LPM.
Answer:
Method 2: Graphical
4-20 mA

FT

Controller input:

FC

4-20 mA

20

Transmitter input:
0-25 LPM
Transmitter output: 4-20 mA

?
mA

Method 1: Mathematical
Use linear relationship between mA (y-axis) and LPM (xaxis).

20 4 mA 4
=
25 0 15 0
mA = 4 + (15 0)

20 4
25 0

mA =13.6
Abdul Aziz Ishak, Universiti Teknologi MARA (2011)

LPM

15

25

Signal Transmissions

Signal Conversions
Example 3:
Input signal to a recorder is between 1 to 5 V. A converter card is used to
convert mA signal from a controller to equivalent voltage signal. Prove that the
converter card can be replaced with a 250 shunt resistor.

4-20 mA

1-5 V

Answer:
Use Ohms Law:
V=IR
R=V/I

4-20 mA

1-5 V

R = 5 / 0.020
R = 250

Abdul Aziz Ishak, Universiti Teknologi MARA (2011)

Signal Transmissions

Signal Conversions
Example 4:
A PID controller is set to manual mode. Then, the controllers output button is pressed until a value of 60%
is shown. The controllers output (CO) is sent to a metering pump to regulate the feed flow rate. Calculate
the current, in mA, that should have been shown on the metering pumps display panel.
0-100% (4-20 mA)

Answer:
Controller output: 0-100% (linearized scale)
Controller output: 4-20 mA
Pumps input:

4-20 mA

Using mathematical method i.e. relationship between

CO (%) vs. pumps input:

20 4 mA 4
=
100 0 60 0
mA = 4 + (60 0 )
mA =13.6

Abdul Aziz Ishak, Universiti Teknologi MARA (2011)

20 4
100 0

Signal Transmissions

Signal Conversions
Example 4:
A PID controller is set to manual mode. Then, the controller output (CO) button is pressed till a value of
60% is shown. The controllers output (MV) is sent to an ATO-type of control valve to regulate flow rate.
Calculate the stem position and the corresponding air pressure output from the I/P.
4-20 mA

I/P

3-15 psi
x: 0-1

Answer:
Controller output: 0-100% (linearized scale)
Controller input:

4-20 mA

I/P input:

4-20 mA

I/P output:

3-15 psi

Stem position, x:

0-1

Stem position = 0.6, since CO represents

the stem position, x.

15 3 psig 3
=
100 0 60 0
psig = 3 + (60 0 )
psig =10.2

Abdul Aziz Ishak, Universiti Teknologi MARA (2011)

15 3
100 0

Signal Transmissions

Signal Conversions
Example 4:
A PID controller is set to manual mode. Then, the controller output (CO) button is pressed till a value of
60% is shown. The controllers output (MV) is sent to an ATO-type of control valve to regulate flow rate.
Calculate the stem position and the corresponding air pressure output from the I/P.
4-20 mA

I/P

3-15 psi
x: 0-1

Answer:
Controller output: 0-100% (linearized scale)
Controller input:

4-20 mA

I/P input:

4-20 mA

I/P output:

3-15 psi

Stem position, x:

0-1

Stem position = 0.6, since CO represents

the stem position, x.

15 3 psig 3
=
100 0 60 0
psig = 3 + (60 0 )
psig =10.2

Abdul Aziz Ishak, Universiti Teknologi MARA (2011)

15 3
100 0

Signal Transmissions

Tutorial #1
pH neutralization control

Reagent

0
100%
Flowrate

4 pH
0
1

4
20 mA
4
20 mA

4
20 mA
1
5 V

Process Description
Wastewater in a pond is measured using a pH sensor. The pH reading will be displayed and sent to a controller. If the
wastewaters pH is acidic, the controller will regulate the dosing pump until the pH of the wastewater is no longer
acidic. The trend of pH in the pond is recorded using a chart recorder.

Abdul Aziz Ishak, Universiti Teknologi MARA (2011)

Signal Transmissions

Tutorial #1

a) In an oxidation pond, pH sensor reads pH of 4. Calculate the pH signal received by the controller in mA.
b) The pH sensor is connected to a transmitter which transmits the signal to the controller and a chart plotter. The chart
plotter input signal is 1 to 5 V. Calculate the input voltage for a measured pH 4.
c) The pH controller is set to manual mode. Then, the manipulated variable (MV) button at the controller is set to 60%
opening. Calculate the signal, in mA, transmitted to the metering pump.
d) If the metering pump had been calibrated to deliver between 0 to 15 liters per minutes (LPM) of flow rate, what would
be the flow rate when the controller showed MV = 60%?
e) The pumping rate of the metering pump is in term of pulse per min. If a pumping rate of 120 pulse per min can deliver
the maximum flow, what would be the pumping rate when MV = 60% was read at the controller?
f) If the pH transmitter read a pH of 14.5, what would the signal transmitted from the controller to the metering pump?

Abdul Aziz Ishak, Universiti Teknologi MARA (2011)

Signal Transmissions

Tutorial #2
Install appropriate hardware for the control of the following bio-fermentor system using a computer.

Variable speed motor

Inverter: Current to
power converter

Dosing pump 3

DAQ PCI card

(Voltage input)

Dosing pump 2

Dosing pump 1

     
Centrifugal pump

 V/I converter
 V/I converter
V/I converter
 V/I converter
 I/V converter
 I/V converter

I/V converters

Abdul Aziz Ishak, Universiti Teknologi MARA (2011)