CONTROL SYSTEM AND

COMPONENT
By-P K Kushwaha
 INTRODUCTION
Disturbance

Controlled Manipulated
Set-point Error Signal Variable
or
Reference Actual
input + + Output
+
+ Controller Actuator + Process
-

Feedback Signal
Sensor
 SYSTEMS IN A PROCESS
• Input
• Signal Processing Unit/Controller
• Actuator/Transducers/Solenoids
• Process
• Sensors/Transducers/Measurements
• Feedback
• Output
• BITE
CONTROL SYSTEM
 INTRODUCTION
A transducer is a device that converts
• Energy from one form to another
• Energy forms can be mechanical, visual, aural, electrical, thermal,
chemical, etc.
• Used to change information into a form that can be easily transferred,
stored, processed, interpreted, etc.

Type of transducers on the basis of method used for

Transduction:
• Active and Passive
• Analog and digital transducer
• Transducer and inverse transducer
• Primary and secondary transducer
TYPE OF TRANSDUCERS
Electro-magnetic
• Receiving antenna
• Transmitting antenna

Electro-chemical
• pH probe
• Fuel Cell

Electro-acoustic
• Loudspeaker
• Microphone

Photo-electric
• LED
• Photo Diode

Thermoelectric
• Thermostat
• Hotplate
 TYPE OF TRANSDUCER

Thermocouple Photovoltaic cell

ACTIVE OR SELF GENERATING

Do not require an external power, and
produce an analog voltage or current
when stimulated by some physical
form of energy .

Tacho-generators Piezoelectric crystals

 TYPE OF TRANSDUCER

Slide-wire resistor Strain gauge

PASSIVE TRANSDUCERS
require an external power, and the output
is a measure of some variation
(resistance inductance or capacitance)

Differential transformer Microphone

 TYPE OF TRANSDUCER

Strain Gauge
LVDT

ANALOG TRANSDUCERS
These transducers convert the input
quantity into an analog output which is a
continuous function of time.

Thermocouple Thermistor
 TYPE OF TRANSDUCER

Pulse Generator Axle Counter

DIGITAL TRANSDUCERS
These transducers convert the input
quantity into an electrical output which is
in the form of pulses.

Optical counter Photo-voltic switch

 TERMINOLOGY
• ACCURACY - how close is the measurement to the actual value?
• RESOLUTION - how fine of a measurement can we make?
• RANGE - what input (and output) values are possible?
• SENSITIVITY - how much does a change in input affect the output?
(also called the scale factor.)
• LINEARITY - does the output change uniformly with the input?
• REPEATABILITY - output signal should be the same whenever the
measured value is the same.
• RESPONSE TIME - how quickly does the transducer respond to
changes in the measured value?
 SOLENOID VALVES
The following factors are important in making the right commercial and
technical choice of valves:
- Valve actuation
・ solenoid
・ pressure
・ proportional
・ motorised
- Number of ways
・ 2/2 Valve
・ 3/2 Valve
 SOLENOID VALVES
- Switching function
・ normally closed (NC)
・ normally open (NO)
- Type of connection
・ threaded
・ flanged
・ weld ends
- Solenoid power supply
・ voltage
・ frequency
 SOLENOID VALVES
- Process fluid
・ neutral to aggressive
・ gas to liquid
・ filtered to contaminated
- Control fluid supply
・ control fluid
・ control pressure
・ temperature of control fluid from - to + °C
・ ambient temperature from - to + °C
 MATERIAL SELECTION RUBBER
NBR Nitrile Butadiene Rubber
HNBR Hydrogenated Nitrile Rubber
EPDM Ethylene Propylene Diene
Monomer Rubber
FPM Fluorocarbon Rubber
CR Polychloroprene Rubber
PTFE Polytetrafluoroethene
FFPM Perfluoride Elastomer
TPE Thermoplastic elastomers
air, water, oil 10 to +90 °C
hot water and steam -20 to +150 °C
alkalis and acids of mid- -20 to +130 °C
range concentration
acids, bases, fuels and oils. -10 to +180 °C
Not resistant to steam
suitable for most refrigerants -20 to +90 °C
Not flexible. Valve bodies and -20 to +200 °C
internal parts
Flexible and excellent sealing -30 to +200 °C
qualities
Very durable yet flexible oils, wide temperature
grease and many solvents range
 MATERIAL SELECTION POLYMERS
PVC Polyvinyl Chloride acids, alkalis, salt solutions 10 to +90 °C
and organic solutions
miscible with water
PVDF Polyvinylidene Fluoride Suitable for nearly all -20 to +100 °C
aggressive fluids
PFA Perfluoralkoxy resistant as PVDF -20 to+150 °C

PP Polypropylene acids, alkalis and salts -20 to+150 °C

POM Polyoxymethylene Not suitable for bases, acids

or oxidising agents
PA Polyamid all neutral fluids and gases

PPS Polyphenylene Sulfide all neutral fluids and gases

 MATERIAL SELECTION METALS
Brass (Ms 58) not suitable for aggressive and ammoniac fluids

Brass (CuZn36Pb2As) Suitable in aggressive fluids and seawater

Aluminum Valve bodies for low pressure application.

Cast iron Suitable for neutral fluids.

Cast steel Valve bodies for high pressure application,

suitable for neutral fluids in high temp

Gun metal Sea water, mildly aggressive water or steam.

Stainless steel Austenitic high-alloy steel for aggressive fluids.

DATA SHEET FOR PRESSURE SWITCH
DATA SHEET FOR PRESSURE SWITCH
 BUILT IN TEST EQUIPMENT
BITE is an acronym for built-in test equipment. The BITE is
characterized primarily as a passive fault management and diagnosis
built into any systems to support the maintenance process. Built-in
test equipment refers to electronic systems that are provided as part of
the system to enable testing and perform diagnostics.
Simulators/signals are used to give input to control unit to check the
operation of I/P and O/P device and compare with the preloaded data
 POINTS TO BE ADDED IN GSQR/RFP/ATP
• Properties /Application(type of media)
• Engineering Specifications/Testing Methodology
– Operating Range
– Proof Pressure
– Burst Pressure
– Operating and leak tests
– Electrical functional tests
– Material identification (Rubber, Polymers and metals)
– Thermal and electrical insulation classification.
 POINTS TO BE ADDED IN GSQR/RFP/ATP
• Product Safety
• Compliance with Government Standards and Regulations
• Emissions
• Environmental
• Safety
• Disposal of contaminated waste
• Feature for Equipment/System/Sub System
• Orientation, Fit and Finish
• Testing Methodology
 DATA SHEET EXAMPLE
Model 3100 OEM Industrial
Pressure Transducer

Model ASL High Accuracy Low

Differential Pressure Transducer

Photo Diode