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Laboratory Report
Experiment #: 2
Instructor:
Programme: Beng3M
To investigate the characteristics of current to pressure converter (I/P) and the pneumatic
control valve.
THEORY:
In the industrial world there are many variables within a process that are necessary for the
plant to operate. There variables need to be monitored and controlled to enable operations
at the plant thus we introduce control valves. These are devices that control a variable
such as temperature, pressure, flow, 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. There are many different types of
control valves. The main difference in the types of control valve is the way in which they are
activated/operated, example electrically, use of hydraulic or pneumatically. 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, 0-10V for HVAC systems, & the introduction of "Smart" systems, HART,
Fieldbus Foundation, & Profibus being the more common protocols. These control vales can be
calibrated for each industry or each process within an industry to meet that specific criterion. The
pneumatic valve will be calibrated such that 4 mA corresponds to the minimum adjustment valve
which fully close the control valve or 20 mA that fully opens the control valve. It would be adjusted
to fall with the two extremes outlined which would partially open the valve. With this calibration
the signal can be converted so as to process control becomes automated.
P/I converters create an interface between pneumatic and electric measuring and control devices,
for example, for connecting pneumatic transmitter to electrical equipment, such as controllers,
computers or control systems. The input variable constitutes a standardized pneumatic signal, the
output variable an electrical DC current signal, however it is normally interpreted as a DC voltage
because of the device’s parallel setup with the measuring instrument.
The fundamental operations of pneumatic to current converter are illustrated in Fig 1a below. The
pressure transducer (1) converts the pressure p of the pneumatic input signal into an electrical
DC voltage signal. The DC voltage signal which is proportional to the pressure is amplified in the
measuring amplifier (3) to a defined level. Both the lower range value and span can be adjusted
using potentiometers on the front panel. The constant DC voltage source (2) is used to supply the
DC voltage at a constant level. Control equipment can be connected to the output circuit. In two-
wire systems, the maximum permissible load impedance is UB = US – UA. US represent the
minimum
supply voltage of the two-wire circuit. The converter requires a minimum natural voltage of UA =
12 V.
There are two types of pressure sensors namely Bourdon tube and Solid state pressure
sensors. The Bourdon tube is a hard metal tube usually made of bronze or brass,is flattened and
one end is closed. The tube is bent into an ark. The openings are attached to a header by which
the pressure can be introduced to the tube. When this happens the tube will deflect when the
pressure inside the tube is different from the pressure outside. If the pressure inside is greater
than the outside pressure then the tube tends to straighten out while if the outside pressure is
greater then the tube curves more. The solid state pressure sensor consists of integrated circuit
technology that measures pressures differences. The basic sensing element is a silicon wafer
acting as a diaphragm that usually deflects in response to a pressure difference. The solid state
pressure sensors are:
1. Sensitive in the range of 10-100mV per kilopascal.
2. Respond to pressure difference in order of 10ms
They are normally used in home appliances such as dishwashers and washing machines.
DIAGRAMS:
Fig 1a
P1 P1
pressure
gauge
pressure pressure
regulator regulator
compressor
Transducer
voltmeter
power
supply
F u llc ru m
L a m in a te d c o re
F o rc e
B ar
F eedback
c o u rs e c o il
D e te c to r
Z e ro
a d ju s tm e n t O s c illa to r
s p r in g
Z e ro
a d ju s tm e n t
s c re w
R1 0 R1 3
R e c e iv e r P o w e r S u p p ly
N i - Span C
P ressu re
b e llo w s
S q u a re
P r im a r y w ave
o s c illa to r
3 - 1 5 psi
Z e r o A d ju s t
In p u t D iff . T r a n s
LVDT P h a se
D em od.
S e co n d ary
DC output
S p a n a d ju s t
assortment of fittings
SPECIFICATION:
A preliminary test was conducted to observe the performance of the instrument initially
2. The power supply (18V) and the voltmeter were connected to the field terminal
3. The calibration pressure was then set to 3 psi and the required output registered on
4. Over a span of 3-15 psi the output voltage was recorded and at 15 psi the
5. Procedure 3 was continuously repeated and the zero screw was used accordingly
6. In adjusting the upper range limit, the span screw was used until at 15psi the
Table 1.1 showing input current, output pressure, valve stem position and % flow rate
Table 12 showing % input current, % output pressure, % valve stem position and % flow
rate
Graph 1.1 showing Input current verse output pressure
The ipt was linear because the values of input compare to output was similar.
The control valve was linear because flow capacity increases linearly with valve travel.
This was also proven when the flow capacity increases exponentially with valve trim travel.
Equal increments of valve travel produce equal percentage changes in the existing Cv.
The linear flow characteristics are usually specified in those process systems where
the majority of the pressure drop is taken through the valve. The piping effects have
a tendency to push the linear characteristics towards the quick open characteristics.
With an Equal Percentage characteristic, the change in flow per unit of valve position
is directly proportional to the flow occurring just before the change is made.
In describing the average sensitivity of the control valve ,20% flowrate increase per
25% valve stem height increase.
DISCUSSION:
During the preliminary test, it was noticed that the variance between the output voltages
for a specific input pressure was at a maximum of 10mV. After calibration, where the
span and zero screws were adjusted to set the standard of 15psi to yield 500mV and 3psi
to yield 100mV; the variance between the output voltages for a specific input pressure
drops to a maximum of 7mV. Even after calibration, there were still variances from the
expected standard. This occurs because of internal friction within the instrument and
connecting wires and possible errors experienced while conducting the experiment. The
1. The pneumatic to current converter consist of a spring that is responsible for the
response of the output voltage to the input pressure. For a specific input pressure,
there are two different output voltages because the spring does not return to its
original position.
2. Overshooting an input pressure and then trying to correct it, increased hysteresis.
3. Sensitivity of the pneumatic instrument. When there was a movement of the knob
to change the pressure, there was a delay in the response of the gauge pressure
4. The use of analogue meters allows for human errors while reading values as
After calibration there was improvement in the accuracy of the instrument as well as
Therefore,
mV/psi = 33.33mV/psi
Thus,
y = 33.33x
Table 3 showing the linear relationship of input pressure and linear voltage.
Grap
600
Accuracy = (max. variance of output/ span) * 100
Accuracy = 1.75%
When comparing Table 2 and Table 3, the values of table 2 are not far off from that of
table 3. Hence, it can be said that the calibrated values are accurate. Also, it can be said
that they are precise as in there was a repeatability of the values. As it regards to linearity
of the instrument
500
CONCLUSION:
The relationship between the input pressure and the output current delivered and to
observe the overall operation of the prescribed instrument was examined. Additionally, it
was observed that when the pressure values were increased and then decreased the output
REFERENCES: