SOLENOID VALVE A solenoid valve is an electromechanically operated valve.

The valve is controlled by an electric current through a solenoid: in the case of a two-port valve the flow is switched on or off; in the case of a three-port valve, the outflow is switched between the two outlet ports. Multiple solenoid valves can be placed together on a manifold. Solenoid valves are the most frequently used control elements in fluidics. Their tasks are to shut off, release, dose, distribute or mix fluids. They are found in many application areas. Solenoids offer fast and safe switching, high reliability, long service life, good medium compatibility of the materials used, low control power and compact design. Besides the plunger-type actuator which is used most frequently, pivoted-armature actuators and rocker actuators are also used. OPERATION There are many valve design variations. Ordinary valves can have many ports and fluid paths. A 2-way valve, for example, has 2 ports; if the valve is open, then the two ports are connected and fluid may flow between the ports; if the valve is closed, then ports are isolated. If the valve is open when the solenoid is not energized, then the valve is termed normally open (N.O.). Similarly, if the valve is closed when the solenoid is not energized, then the valve is termed normally closed. There are also 3-way and more complicated designs. A 3-way valve has 3 ports; it connects one port to either of the two other ports (typically a supply port and an exhaust port). Solenoid valves are also characterized by how they operate. A small solenoid can generate a limited force. If that force is sufficient to open and close the valve, then a direct acting solenoid valve is possible. An approximate relationship between the required solenoid force Fs, the fluid pressure P, and the orifice area A for a direct acting solenoid value is:

Where d is the orifice diameter. A typical solenoid force might be 15 N (3.4 lbf). An application might be a low pressure (e.g., 10 pounds per square inch (69 kPa)) gas with a small orifice diameter (e.g., 38 in (9.5 mm) for an orifice area of 0.11 sq in (7.1105 m2) and approximate force of 1.1 lbf (4.9 N)). When high pressures and large orifices are encountered, then high forces are required. To generate those forces, an internally piloted solenoid valve design may be possible. In such a design, the line pressure is used to generate the high valve forces; a small solenoid controls how the line pressure is used. Internally piloted valves are used in dishwashers and irrigation systems where the fluid is water, the pressure might be 80 pounds per square inch (550 kPa) and the orifice diameter might be 34 in (19 mm). In some solenoid valves the solenoid acts directly on the main valve. Others use a small, complete solenoid valve, known as a pilot, to actuate a larger valve. While the second type is actually a solenoid valve combined with a pneumatically actuated valve, they are sold and packaged as a single unit referred to as a solenoid valve. Piloted valves require much less power to control, but they are noticeably slower. Piloted solenoids usually need full power at

all times to open and stay open, where a direct acting solenoid may only need full power for a short period of time to open it, and only low power to hold it. A direct acting solenoid valve typically operates in 5 to 10 milliseconds. The operation time of a piloted valve depends on its size; typical values are 15 to 150 milliseconds.[4] INTERNALLY PILOTED While there are multiple design variants, the following is a detailed breakdown of a typical solenoid valve design. A solenoid valve has two main parts: the solenoid and the valve. The solenoid converts electrical energy into mechanical energy which, in turn, opens or closes the valve mechanically. A direct acting valve has only a small flow circuit, shown within section E of this diagram (this section is mentioned below as a pilot valve). In this example, a diaphragm piloted valve multiplies this small pilot flow, by using it to control the flow through a much larger orifice. Solenoid valves may use metal seals or rubber seals, and may also have electrical interfaces to allow for easy control. A spring may be used to hold the valve opened (normally open) or closed (normally closed) while the valve is not activated.

A-Input side B-Diaphragm C-Pressure chamber D-Pressure relief passage

E-Solenoid F- Output side The diagram to the right shows the design of a basic valve, controlling the flow of water in this example. At the top figure is the valve in its closed state. The water under pressure enters at A. B is an elastic diaphragm and above it is a weak spring pushing it down. The diaphragm has a pinhole through its center which allows a very small amount of water to flow through it. This water fills the cavity C on the other side of the diaphragm so that pressure is equal on both sides of the diaphragm, however the compressed spring supplies a net downward force. The spring is weak and is only able to close the inlet because water pressure is equalized on both sides of the diaphragm. Once the diaphragm closes the valve, the pressure on the outlet side of its bottom is reduced, and the greater pressure above holds it even more firmly closed. Thus, the spring is irrelevant to holding the valve closed. The above all works because the small drain passage D was blocked by a pin which is the armature of the solenoid E and which is pushed down by a spring. If current is passed through the solenoid, the pin is withdrawn via magnetic force, and the water in chamber C drains out the passage D faster than the pinhole can refill it. The pressure in chamber C drops and the incoming pressure lifts the diaphragm, thus opening the main valve. Water now flows directly from A to F. When the solenoid is again deactivated and the passage D is closed again, the spring needs very little force to push the diaphragm down again and the main valve closes. In practice there is often no separate spring; the elastomer diaphragm is molded so that it functions as its own spring, preferring to be in the closed shape. From this explanation it can be seen that this type of valve relies on a differential of pressure between input and output as the pressure at the input must always be greater than the pressure at the output for it to work. Should the pressure at the output, for any reason, rise above that of the input then the valve would open regardless of the state of the solenoid and pilot valve. COMPONENTS

Example core tubes. Non-magnetic core tubes are used to isolate the fluid from the coil. The core tube encloses the plugnut, the core spring, and the core. The coil slips over the

core tube; a retaining clip engages the depression near the closed end of the core tube and holds the coil on the core tube. Solenoid valve designs have many variations and challenges. Common components of a solenoid valve: Solenoid subassembly Retaining clip (a.k.a. coil clip) Solenoid coil (with magnetic return path) Core tube (a.k.a. armature tube, plunger tube, solenoid valve tube, sleeve, guide assembly) Plugnut (a.k.a. fixed core) Shading coil (a.k.a. shading ring) Core spring (a.k.a. counter spring) Core (a.k.a. plunger, armature) Core tubebonnet seal Bonnet (a.k.a. cover) Bonnetdiaphrambody seal Hanger spring Backup washer Diaphram Bleed hole Disk Valve body Seat

The core or plunger is the magnetic component that moves when the solenoid is energized. The core is coaxial with the solenoid. The core's movement will make or break the seals that control the movement of the fluid. When the coil is not energized, springs will hold the core in its normal position. The plugnut is also coaxial. The core tube contains and guides the core. It also retains the plugnut and may seal the fluid. To optimize the movement of the core, the core tube needs to be nonmagnetic. If the core tube were magnetic, then it would offer a shunt path for the field lines. In some designs, the core tube is an enclosed metal shell produced by deep drawing. Such a design simplifies the sealing problems because the fluid cannot escape from the enclosure, but the design also increases the magnetic path resistance because the magnetic path must traverse the thickness of the core tube twice: once near the plugnut and once near the core. In some other designs, the core tube is not closed but rather an open tube that slips over one end of the plugnut. To retain the plugnut, the tube might be crimped to the plugnut. An O-ring seal between the tube and the plugnut will prevent the fluid from escaping. The solenoid coil consists of many turns of copper wire that surround the core tube and induce the movement of the core. The coil is often encapsulated in epoxy. The coil also has an iron frame that provides a low magnetic path resistance. MATERIALS

The valve body must be compatible with the fluid; common materials are brass, stainless steel, aluminum, and plastic. The seals must be compatible with the fluid. To simplify the sealing issues, the plugnut, core, springs, shading ring, and other components are often exposed to the fluid, so they must be compatible as well. The requirements present some special problems. The core tube needs to be non-magnetic to pass the solenoid's field through to the plugnut and the core. The plugnut and core need a material with good magnetic properties such as iron, but iron is prone to corrosion. Stainless steels can be used because they come in both magnetic and non-magnetic varieties. For example, a solenoid valve might use 304 stainless steel for the body, 305 stainless steel for the core tube, 302 stainless steel for the springs, and 430 F stainless steel (a magnetic stainless steel) for the core and plugnut. TYPES Many variations are possible on the basic, one-way, one-solenoid valve described above: one- or two-solenoid valves; direct current or alternating current powered different number of ways and positions

COMMON USES Solenoid valves are used in fluid power pneumatic and hydraulic systems, to control cylinders, fluid power motors or larger industrial valves. Automatic irrigation sprinkler systems also use solenoid valves with an automatic controller. Domestic washing machines and dishwashers use solenoid valves to control water entry into the machine. Solenoid valves are used in dentist chairs to control air and water flow. In the paintball industry, solenoid valves are usually referred to simply as "solenoids." They are commonly used to control a larger valve used to control the propellant (usually compressed air or CO2). In addition to this, these valves are now being used in household water purifiers (RO systems). Besides controlling the flow of air and fluids, solenoids are used in pharmacology experiments, especially for patch-clamp, which can control the application of agonist or antagonist. HOW DOES A SOLENOID VALVE WORK? The solenoid valve uses an electric current which moves the solenoid. This pulls a piston preventing it from stopping the flow of air and fluid. The valve will need a constant flow of electrical current to remain open because when there is no current flow, the electromagnetic field scatters and the valve returns to its original position. DIFFERENTIAL PRESSURE FLOWMETERS In a differential pressure drop device the flow is calculated by measuring the pressure drop over an obstructions inserted in the flow. The differential pressure flowmeter is based on the Bernoullis Equation, where the pressure drop and the further measured signal is a function of the square flow speed.

Orifice Plate With an orifice plate, the fluid flow is measured through the difference in pressure from the upstream side to the downstream side of a partially obstructed pipe. The plate obstructing the flow offers a precisely measured obstruction that narrows the pipe and forces the flowing fluid to constrict.

The orifice plates are simple, cheap and can be delivered for almost any application in any material. The Turn Down Rate for orifice plates are less than 5:1. Their accuracy are poor at low flow rates. A high accuracy depend on an orifice plate in good shape, with a sharp edge to the upstream side. Wear reduces the accuracy.

Venturi Tube Due to simplicity and dependability, the Venturi tube flowmeter is often used in applications where it's necessary with higher Turn Down Rates, or lower pressure drops, than the orifice plate can provide. In the Venturi Tube the fluid flowrate is measured by reducing the cross sectional flow area in the flow path, generating a pressure difference. After the constricted area, the fluid is passes through a pressure recovery exit section, where up to 80% of the differential pressure generated at the constricted area, is recovered.

With proper instrumentation and flow calibrating, the Venturi Tube flowrate can be reduced to about 10% of its full scale range with proper accuracy. This provides a Turn Down Rate 10:1. Flow Nozzles Flow nozzles are often used as measuring elements for air and gas flow in industrial applications.

The flow nozzle is relative simple and cheap, and available for many applications in many materials. The Turn Down Rate and accuracy can be compared with the orifice plate.

The Sonic Nozzle - Critical (Choked) Flow Nozzle

When a gas accelerate through a nozzle, the velocity increase and the pressure and the gas density decrease. The maximum velocity is achieved at the throat, the minimum area, where it breaks Mach 1 or sonic. At this point it's not possible to increase the flow by lowering the downstream pressure. The flow is choked. This situation is used in many control systems to maintain fixed, accurate, repeatable gas flow rates unaffected by the downstream pressure. Recovery of Pressure Drop in Orifices, Nozzles and Venturi Meters. After the pressure difference has been generated in the differential pressure flow meter, the fluid pass through the pressure recovery exit section, where the differential pressure generated at the constricted area is partly recovered.

As we can see, the pressure drop in orifice plates are significant higher than in the venturi tubes. Variable Area Flowmeter or Rotameter

The rotameter consists of a vertically oriented glass (or plastic) tube with a larger end at the top, and a metering float which is free to move within the tube. Fluid flow causes the float to rise in the tube as the upward pressure differential and buoyancy of the fluid overcome the effect of gravity.

The float rises until the annular area between the float and tube increases sufficiently to allow a state of dynamic equilibrium between the upward differential pressure and buoyancy factors, and downward gravity factors. The height of the float is an indication of the flow rate. The tube can be calibrated and graduated in appropriate flow units. The rotameter meter typically have a TurnDown Ratio up to 12:1. The accuracy may be as good as 1% of full scale rating. Magnetic floats can be used for alarm and signal transmission functions. Velocity Flowmeters

In a velocity flowmeter the flow is calculated by measuring the speed in one or more points in the flow, and integrating the flow speed over the flow area.

Pitot Tubes The pitot tube are one the most used (and cheapest) ways to measure fluid flow, especially in air applications as ventilation and HVAC systems, even used in airplanes for the speed measurent.

The pitot tube measures the fluid flow velocity by converting the kinetic energy of the flow into potential energy. The use of the pitot tube is restricted to point measuring. With the "annubar", or multi-orifice pitot probe, the dynamic pressure can be measured across the velocity profile, and the annubar obtains an averaging effect. Calorimetric Flowmeter The calorimetric principle for fluid flow measurement is based on two temperature sensors in close contact with the fluid but thermal insulated from each other.

One of the two sensors is constantly heated and the cooling effect of the flowing fluid is used to monitor the flowrate. In a stationary (no flow) fluid condition there is a constant temperature difference between the two temperature sensors. When the fluid flow increases, heat energy is drawn from the heated sensor and the temperature difference between the sensors are reduced. The reduction is proportional to the flow rate of the fluid. Response times will vary due the thermal conductivity of the fluid. In general lower thermal conductivity require higher velocity for proper measurement. The calorimetric flowmeter can achieve relatively high accuracy at low flow rates. Turbine Flowmeter There is many different manufacturing design of turbine flow meters, but in general they are all based on the same simple principle: If a fluid moves through a pipe and acts on the vanes of a turbine, the turbine will start to spin and rotate. The rate of spin is measured to

calculate the flow. The turndown ratios may be more than 100:1 if the turbine meter is calibrated for a single fluid and used at constant conditions. Accuracy may be better than +/0,1%. Vortex Flow Meter An obstruction in a fluid flow creates vortices in a downstream flow. Every obstruction has a critical fluid flow speed at which vortex shedding occurs. Vortex shedding is the instance where alternating low pressure zones are generated in the downstream.

These alternating low pressure zones cause the obstruction to move towards the low pressure zone. With sensors gauging the vortices the strength of the flow can be measured. Electromagnetic Flowmeter An electromagnetic flowmeter operate on Faraday's law of electromagnetic induction that states that a voltage will be induced when a conductor moves through a magnetic field. The liquid serves as the conductor and the magnetic field is created by energized coils outside the flow tube. The voltage produced is directly proportional to the flow rate. Two electrodes mounted in the pipe wall detect the voltage which is measured by a secondary element. Electromagnetic flowmeters can measure difficult and corrosive liquids and slurries, and they can measure flow in both directions with equal accuracy. Electromagnetic flowmeters have a relatively high power consumption and can only be used for electrical conductive fluids as water. Ultrasonic Doppler Flowmeter The effect of motion of a sound source and its effect on the frequency of the sound was observed and described by Christian Johann Doppler. The frequency of the reflected signal is modified by the velocity and direction of the fluid flow If a fluid is moving towards a transducer, the frequency of the returning signal will increase. As fluid moves away from a transducer, the frequency of the returning signal decrease. The frequency difference is equal to the reflected frequency minus the originating frequency and can be use to calculate the fluid flow speed. The Ultrasonic Doppler and Time of Flight Flowmeter Positive Displacement Flowmeter The positive displacement flowmeter measures process fluid flow by precision-fitted rotors as flow measuring elements. Known and fixed volumes are displaced between the rotors. The rotation of the rotors are proportional to the volume of the fluid being displaced.

The number of rotations of the rotor is counted by an integral electronic pulse transmitter and converted to volume and flow rate. The positive displacement rotor construction can be done in several ways: Reciprocating piston meters are of single and multiple-piston types. Oval-gear meters have two rotating, oval-shaped gears with synchronized, close fitting teeth. A fixed quantity of liquid passes through the meter for each revolution. Shaft rotation can be monitored to obtain specific flow rates. Nutating disk meters have moveable disks mounted on a concentric sphere located in spherical side-walled chambers. The pressure of the liquid passing through the measuring chamber causes the disk to rock in a circulating path without rotating about its own axis. It is the only moving part in the measuring chamber. Rotary vane meters consists of equally divided, rotating impellers, two or more compartments, inside the meter's housings. The impellers are in continuous contact with the casing. A fixed volume of liquid is swept to the meter's outlet from each compartment as the impeller rotates. The revolutions of the impeller are counted and registered in volumetric units. The positive displacement flowmeter may be used for all relatively nonabrasive fluids such as heating oils, lubrication oils, polymer additives, animal and vegetable fat, printing ink, freon, and many more. Accuracy may be up to 0.1% of full rate with a TurnDown of 70:1 or more. Mass Flowmeters Mass meters measure the mass flow rate directly. Thermal Flowmeter The thermal mass flowmeter operates independent of density, pressure, and viscosity. Thermal meters use a heated sensing element isolated from the fluid flow path where the flow stream conducts heat from the sensing element. The conducted heat is directly proportional to the mass flow rate and the he temperature difference is calculated to mass flow. The accuracy of the thermal mass flow device depends on the calibrations reliability of the actual process and variations in the temperature, pressure, flow rate, heat capacity and viscosity of the fluid. Coriolis Flowmeter Direct mass measurement sets Coriolis flowmeters apart from other technologies. Mass measurement is not sensitive to changes in pressure, temperature, viscosity and density. With the ability to measure liquids, slurries and gases, Coriolis flowmeters are universal meters. Coriolis Mass Flowmeter uses the Coriolis effect to measure the amount of mass moving through the element. The fluid to be measured runs through a U-shaped tube that is caused to vibrate in an angular harmonic oscillation. Due to the Coriolis forces, the tubes will deform and an additional vibration component will be added to the oscillation. This

additional component causes a phase shift on some places of the tubes which can be measured with sensors. The Coriolis flow meters are in general very accurate, better than +/-0,1% with an turndown rate more than 100:1. The Coriolis meter can also be used to measure the fluids density. Open Channel Flowmeters A common method of measuring flow through an open channel is to measure the height of the liquid as it passes over an obstruction as a flume or weir in the channel.

Common used is the Sharp-Crested Weir, the V-Notch Weir, the Cipolletti weir, the Rectangular-Notch Weir, the Parshall Flume or Venturi Flume. Weir Flow Measurement Standards - Important and common used standards within weir flow measurement Measuring Flow Rate with Weirs - Weirs are often used for measuring flow rates in open channels and rivers in connection to water supply and sewage plants

MAKALAH PENGENDALIAN PROSES

CONTROL VALVE AND MEASURE DEVICE

Disusun Oleh : Muh Aditya Surya Aditama NIM.1231410116

JURUSAN TEKNIK KIMIA POLITEKNIK NEGERI MALANG

2014