summer training at

HINDUSTAN ZINC LIMITED,DEBARI

from 1 st June to 30 th June, 2011

Presentation on:-

FUNCTIONING OF CONTROL VALVE THROUGH DCS

Submitted To: Mr. NAVNEET AGARWAL Placement & Training Incharge Dept. of Electronics and Communication Engg. C.T.A.E.,UDAIPUR

CONTENTS
INTRODUCTION TO HZL INTRODUCTION TO CONTROL VALVE CHARACTERISTICS OF CONTROL VALVE TYPES OF CONTROL VALVE

MODES OF OPERATION OF CONTROL VALVE

DISTRIBUTED CONTROL SYSTEM (DCS) PROPORTIONAL INTEGRAL DERIVATIVE CONTROLLER

INTRODUCTION TO HZL
HZL was incorporated in January

1966 as a public sector company after the take over of the erstwhile Metal Corporation of India Limited (MCI), to develop mining and smelting capacities to substantially meet the domestic demand of zinc and lead metals.
SMELTERS: DEBARI CHANDERIA VISHAKHAPATNAM RAW MATERIAL SUPPLIERS: ZAWAR MINES RAJPURA DARIBA MINES RAMPUR AGUCHA MINES

INTRODUCTION TO ZINC SMELTER DEBARI

LOCATION PROCESS OPERATING CAPACITY : : : 14km East of Udaipur Hydrometallurgical Zinc- 80,000MT Sulphuric Acid- 130,000MT Cadmium- 250MT Zinc Ingots (99.995%) Sulphuric Acid (99.5%) Cadmium (99.5%) 38-40MW TATA BHEL STEEL COMPANIES

PRODUCTION PERFORMANCE:

POWER DEMAND PRODUCT BUYERS

: :

ZINC SMELTER DEBARI(ZSD)

VARIOUS DEPARTMENTS
PRODUCTION DEPTT.
LEACHING & PURIFICATION PLANT ROASTER & ACID PLANT ZINC ELECTROLYSIS & MELTING PLANT

ZSD

ADMINISTRATION DEPTT.

SAFETY DEPTT. SERVICE DEPTT. STORES DEPTT. SALES DEPTT.

FINANCE DEPTT.

INTRODUCTION TO CONTROL VALVE

Valves are used to control conditions such as flow, pressure, temperature and liquid level. Fully or partially opening or closing in response to signals received recieved from controllers that compare a "setpoint" to a "process variable" whose value is provided by sensors that monitor changes in such conditions. Opening or closing of valves is done by means of electrical, hydraulic or pneumatic systems.
Positoners are used to control the opening or closing of the actuator based on Electric, or Pnuematic Signals.

CHARACTERSTICS OF CONTROL VALVES

Broadly classified as:
MANUALValues are mentioned manually. AUTOMATICValues are regulated through logical programming.

Based on two Signals:

ANALOG4-20 mAmps.

DIGITALstart: stop:

denoted by 1.
denoted by 0.

 Output is between 0 100% ie..percentage of valve opened. The range is divided into 4 mAmps for every 25% . In the field side current is converted into pressure by I to P converter according to which valve is opened and closed.

% OPENING
0 25 50 75

CURRENT (mAmps)
4 8 12 16

O/P PRESSURE (bar)

0.2 0.4 0.6 0.8

100

20

1.0

TABLE

TYPES OF CONTROL VALVE

CONTROL VALVE

BUTTERFLY VALVE

THREE WAY VALVE

PNEUMATIC VALVE

HYDRAULIC VALVE

MOTORISED VALVE

SOLENOID VALVE

PNEUMATIC VALVE : It

operates by a combination of force created by air and spring force. A rubber diaphragm separates the actuator housing into two air chambers. The upper chamber receives supply air. The bottom chamber contains a spring that forces the diaphragm against mechanical stops in the upper chamber.
The position of the valve is controlled

by varying supply air pressure in the upper chamber.

As supply air pressure is increased

from zero, its force on top of the diaphragm begins to overcome the opposing force of the spring. This causes the diaphragm to move downward and the control valve to close.

Pneumatic valves are normally used to control processes requiring quick and accurate response, as they do not require a large amount of motive force.

HYDRAULIC VALVE : It consists of a cylinder, piston, spring, hydraulic supply and return line, and stem. The piston slides vertically inside the cylinder and separates cylinder into two chambers. The upper chamber contains the spring and the lower chamber contains hydraulic oil. The stem transmits the motion of the piston to a valve. Initially, with no hydraulic fluid pressure, the spring force holds the valve in the closed position. As fluid enters the lower chamber, pressure in the chamber increases.when the hydraulic force due to the pressure is greater than the spring force, the piston moves upward, the spring compresses and the valve begins to open.

 By regulating the

amount of oil supplied or drained, the valve can be opened between fully opened and closed.
When a large

amount of force is required to operate a valve hydraulic valves are normally used.

SOLENOID VALVES : It consists of a coil, armature,

spring, and stem.

The coil is connected to an external

current supply.The spring rests on the armature to force it downward.

When current flows through the coil,

a magnetic field forms around the coil. The magnetic field attracts the armature toward the center of the coil. As the armature moves upward, the spring collapses and the valve opens.
When the circuit is opened and

current stops flowing to the coil, the magnetic field collapses. This allows the spring to expand and shut the valve.

Advantages: quick operation easier to install Disadvantages: They have only two positions: fully open and fully closed. They dont produce much force, so they usually only operate relatively small valves.

MODES OF OPERATION OF CONTROL VALVE

MANUAL-:
Controlling of control valve manually is called manual mode. In this the user is required to give commands. For this following parameters are needed to be set: SP- Set point The value set by the user for the operation of valve. PV- Process value The value at which the processing takes place. OP- Operating value The value at which the valve operates in the field.

 AUTO-:
Controlling of control valve through loop tuning is called automatic controlling. It depends on condition.

For this following parameters are needed to be set:-

SP- Set point The value set by the user for the operation of valve.

PV- Process variable The value at which the processing takes place.
OP- Operating value The value at which the valve operates in the field.

DISTRIBUTED CONTROL SYSTEM

A distributed control system (DCS)
refers to a control system usually of a manufacturing system, process or any kind of dynamic system, in which the controller elements are not central in location (like the brain) but are distributed throughout the system with each component subsystem controlled by one or more controllers.

The entire system of controllers is

connected by networks

for

communication and monitoring.

A DCS uses Input & output modules

which form component parts of the DCS. The input modules receive information from input instruments in the process and transmit instructions to the output instruments in the field.

THE DCS SYSTEM IN PLANT OPERATION

Six C300 controllers are used for controlling the whole plant operation. The operational logic is stored in these controllers. Process Manager Input Output cards (PMI/Os) are provided for data acquisition from field. FTE(Fault Tolerant Ethernet) based communication networks are used to provide communication between operating plants and controllers.

Field terminated Assembly Cards (FTA) provides path to the control signals. The signals are forwarded to the fields through cables.
The HMI system presents the information to the operating personnel graphically, in the form of a mimic diagram. This means that the operator can see a schematic representation of the plant being controlled.

HUMAN MACHINE INTERFACE

CONTROLLER
Logical programming

slots

FTA cards

Path for transmission

CONTROL VALVE

I TO P CONVERTER
Analog current to pressure conversion

Through cables

TERMINAL BLOCK (TB)

Analog Feedback from positioner

OPENING AND CLOSING OF CONTROL VALVE THROUGH DCS

LOGICAL PROGRAMMING BLOCK FOR CONTROLLONG OF CONTROL VALVE :-

PID Block: The PID block is a regulator control block that operates as a proportionalintegral-derivative (PID) controller. It supports the Ideal form of calculating the PID terms. The PID block has two analog inputs a process variable (PV) and a set point (SP). The difference between PV and SP is the error and this block calculates the control output(OP) that would drive the error to zero.

The following equations are supported:Proportional, Integral, and Derivative (PID) on the error

Proportional and Integral (PI) on the error and Derivative (D) on changes in PV
Integral (I) on the error and Proportional and Derivative (PD) on changes in PV Integral (I) only Proportional (P) only