Control System Components (CSC)

Questions 1 – 7
Q.1.Explain Air compressor and Pneumatic air supply system.
Air Compressor :-
• An air compressor, as the name indicates, is a machine to compresses the
air and raises its pressure.
• The air compressor absorbs air from the atmosphere and compresses it.
• Then it sends to a storage vessel under high pressure.
• From the storage vessel, it can be carried by pipeline to a location where a
supply of compressed air is needed.
• Since air compression needs some work to be done on it, hence a
compressor should be driven by some prime mover.
TYPES OF AIR COMPRESSOR-

1. Reciprocating air compressor

2. Rotary air compressor
3. Centrifugal air compressor
4. Axial air compressor.

1.Reciprocating air compressor

• A reciprocating air compressor is a type of positive displacement
compressor that uses a piston.
• The piston is driven by the crankshaft to transfer the high-pressure gases
into the cylinder.
• In these types of air compressors, initially, the gas enters from the
suction manifold.
• This gas is flowing through a compression cylinder where it gets
compressed by an attached piston.

2. Rotary air compressor.

• A rotary air compressor, which is the simplest compressor, consists of
two rotors with lobes rotating in an air-tight casing that has an inlet and
outlet ports.
• Its action resembles that of a gear pump.
• There are many designs of a wheel, but they generally have two or three
lobes.
• The lobes are made that they provide an air-tight joint at their point of
contact.
3. Centrifugal Air Compressor

• A centrifugal blower compressor is a common type, has a rotor in which

several types of curved vanes are arranged symmetrically.
• The rotor revolves in an air-tight casing with inlet and outlet points.
• In these types of air compressors, the casing for the compressor is so
designed that the kinetic energy of the air is converted into pressure
energy before it leaves the casing as shown in the figure.
• Mechanical energy is given to the rotor from an external source.

5. Axial air compressor.

• An axial-flow compressor, in its simplest form, has a number of
rotating blades attached to a revolving drum.
• The drum rotates inside an air-tight casing to which are fixed stator
blade rows as shown in the figure.
• The blades are produced of an aerofoil section to lower the loss
created by turbulence and boundary separation.
• Mechanical energy is given to the rotating shaft, which turns the drum.

Pneumatic air supply system :-

• A pneumatic system is a collection of interconnected components using

compressed air to do work for automated equipment.
• Examples can be found in industrial manufacturing, a home garage or a
dentist office.
• This work is produced in the form of linear or rotary motion.
• The compressed air or pressurized gas is usually filtered and dried to
protect the cylinders, actuators, tools and bladders performing the work.
• Some applications require a lubrication device that adds an oil mist to the
closed pressurized system.
• Pneumatic systems use a variety of components to affect movement, as
well as for control purposes.
• For efficient movement and control, the following pneumatic system
components include:

Air Compressor :-

As an air exhausting mechanism, this pneumatic equipment component sucks in

outside air, compresses it and harnesses the air for use in your process.
Pneumatic Cylinders :-

A mechanical device used in a pneumatic system that produces force via

compressed air is a cylinder. Once pneumatic cylinders are actuated,
compressed air enters into the tube at one end of the piston and imparts force on
the piston. This causes the piston to move.

Pneumatic Fittings :-

Fittings provide control for your process. They connect valves and provide leak-
free pneumatic movement.

Tubing :-

Pneumatic tubing and hose convey pressurized air to actuators, valves, tools and
other devices.

Pneumatic Valves :-

To ensure your pneumatic device runs efficiently, you need controlled air flow.

Q.2. Give classification of Hydraulic pumps and explain any one of them.

• When a hydraulic pump goes into operation, it performs to key functions.

Firstly, its mechanical action creates a vacuum at the pump inlet which
allows the atmospheric pressure to force liquid from the main reservoir
into the inlet line to the pump.
• Secondly, its mechanical action delivers this liquid to the pump outlet and
forces it into the hydraulic system.
• A pump produces flow and liquid movement, which does not actually
generate any form of pressure.
• It produces the flow necessary for the development of pressure, which is
a function of resistance to fluid flow in the system.
• The pressure of the fluid at the pump outlet is zero, for a pump which is
not connected to a system.
• If the pump is delivering into a system, then the pressure will only rise to
the level necessary to overcome the resistance of the load itself.
• All pumps are classified as either positive-displacement or non-positive-
displacement. Most pumps which are used in hydraulic systems are
positive-displacements.
 • Non-positive-displacement pumps produce a continuous flow. However,
as they do not provide an internal, positive seal against slippage, its
output varies considerable as pressure varies.
• Both propeller pumps and centrifugal pumps are typical examples of a
non-positive design.
• If the output port of these models were to be blocked off, either as a result
of mistaken installation of fluid contamination, the pressure itself would
rise whilst the output would decrease to zero.

The Types Of Hydraulic Pumps

• Reciprocating Pumps
• External/Internal Gear Pumps
• Lobe Pumps
• Screw Pumps

Lobe pumps-

• Lobe pumps are similar to external gear pumps in operation in that fluid
flows around the interior of the casing.
• Unlike external gear pumps, however, the lobes do not make contact.
• Lobe contact is prevented by external timing gears located in the gearbox.
• Pump shaft support bearings are located in the gearbox, and since the
bearings are out of the pumped liquid, pressure is limited by bearing
location and shaft deflection which reduces the noise levels of this pump.

• Lobe pump is one of the Positive Displacement Pump rotary type.

• As the lobes come out of mesh, they create an expanding volume on the
inlet side of the pump.
• Material to be pumped (liquid, or gas, possibly containing small solid
particles) flows into this cavity.
• Rotation of the lobes past the inlet port creates enclosed volumes of
material between the rotors and the pump casing.
• The material travels around the interior of the casing in these enclosed
volumes between the rotor's lobes and the casing — it does not pass
between the lobes.

Q. 3.Explain with a suitable diagram SMART transmitter.

DONE BY SANKET QUESTION NO.40
Q.4. What is a control valve ? Describe Control valve plug characteristics
• Control valves are used in many processes to control flow, pressure,
temperature or other variables.
•
• The type of valve used will depend on the size of the pipe, the overall
pressure that the system operates, the flowing media, process conditions,
and other factors.
• There is also a balance between the cost of the valve and the cost
benefits associated with tighter control.
• Valve vary the flow of fluid through it by means of the change of
pressure to the valve top.
• The relation between valve stem position and flow through the valve is
known as valve characteristics.
• The amount of fluid passing through a valve at any time depends upon
the opening between the plug and seat.
• Hence there is a relationship between stem position, plug position and
the rate of flow, which is described in terms of flow characteristics of a
valve.
• The two types of valve characteristics are inherent and installed flow
characteristics.
• Installed Characteristics:
• The inherent flow characteristic of the control valve is the relationship
between the flow and travel of the valve to a constant pressure drop
across the valve.
• The inherent flow characteristics of the valve are determined by the
valve orifice and plug geometry.

• There are three types of inherent flow characteristics, namely linear, fast
opening and equal percentage

• Valves of any size or inherent flow characteristic which are subjected to

the same volumetric flow rate and differential pressure will have exactly
the same orifice pass area.

• However, different valve characteristics will give different ‘valve

openings’ for the same pass area.
 Linear flow Characteristics:

• The linear flow characteristics show that the flow rate is directly
proportional to the path of the valve.

• Control valves with linear flow characteristics are commonly specified

for liquid level control.

• The sensitivity of a control valve with linear flow characteristic is

always constant.

Equal percentage characteristic:

• These valves have a valve plug shaped so that each increase in valve lift
increases the flow rate in a certain percentage of the previous flow.

• The relationship between the elevation of the valve and the size of the
hole (and, therefore, the flow) is not linear but logarithmic.

Fast opening characteristic:

• The valve plug characteristic of quick opening will give a large change
in the flow rate for a small valve lift from the closed position.

• Quick opening valves tend to be electrically or pneumatically driven and

used for on / off control.

• The type of automatic action control valve tends to have a plug shape
similar to the quick opening plug.

• The characteristic of the control valve chosen for an application should

result in a direct relationship between valve opening and flow, over as
much of the travel of the valve as possible.

Q. 5. Explain the alarm annunciator and explain its Sequence.

DONE BY SANKET 5 AND 42 SAME QUESTION

Q.6. Explain working of current to pneumatic converter and write its
specifications

• Current to Pressure Converter works on flapper nozzle method. The

input is 4 to 20mA signal and the equivalent output is 3 to 15 PSI
pressure.
• In the Current to Pressure converter, we usually give input current signal
as 4 – 20 mA .
• We also give a continuous supply of 20 P.S.I to the Flapper Nozzle
assembly.
• As we give input current signal, Electromagnet gets activated.
• If the current is more, then the power of magnet will get increased. The
Flapper of the Flapper-Nozzle instrument is connected to Pivot so that it
can move up and down and a magnetic material was attached to other end
of flapper and it is kept near the electromagnet.
• As the magnet gets activated. the flapper moves towards the
electromagnet and the nozzle gets closed to some extent.
• So the some part of 20 P.S.I supplied will escape through nozzle and
remaining pressure will come as output.

• If the current signal is high, then power of the magnet will increase, then
flapper will move closer to the nozzle, so less pressure will escape
through nozzle and output pressure increases.

• In this way the output pressure will be proportional to the input current.
• For the input current of 4 – 20 mA we can get the output pressure of 3 –
15 P.S.I.
Q.7. Explain with a suitable diagram working of Motion balance valve
positioner. state advantages of valve positioner.

A block diagram to understand working of motion balance valve positioner is

shown as follows-

• In motion-balance mechanism, an increasing signal pressure causes the

beam to advance toward the nozzle, generating increased nozzle
backpressure which then causes the pneumatic amplifying relay to send
more air pressure to the valve actuator.
• As the valve stem lifts up, the upward motion imparted to the right-hand
end of the beam counters the beam’s previous advance toward the nozzle.
• When equilibrium is reached, the beam will be in an angled position with
the bellows’ motion balanced by valve stem motion.

Advantage of valve positioner.

• A positioner allows you to put distance between the controller and the
control valve; therefore, more flexible configurations and functions
will be provided.
• They remove the effects of large distances between valve and
positioner.
• They minimize the effects of friction.
• They eliminate hysteresis which reduces productivity.
• It allows for split ranging. For instance, one controller for two valves.
• It allows use of piston actuators with high instrument air supply
pressures.
• It allows a wide range of flow variation. For instance, operate at less
than 10% travel under normal conditions.
• It allows the use of characteristic cams in rotary valves.