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Measurement and Control Basics 3rd Edition (complete book)

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Appendix C – Answers to Exercises

365

Figure 10-5. Using this test setup, control valve manufacturers determine and publish Cv valves for their valves.

10.4The volumetric flow rate is 1060.2 cfm.

10.5The valve-sizing coefficient is 56.57 and a 3 in. valve should be selected.

10.6The valve will not cavitate and the valve-sizing coefficient is 253.

10.7If the pressure at the outlet of the valve is still below the vapor pressure of the liquid, bubbles will remain in the downstream system and result in flashing. If the downstream pressure recovery is sufficient to raise the outlet pressure above the liquid vapor pressure, the bubbles will collapse, or implode, producing cavitation.

10.8The torque constant is 0.143oz-in./v and damping constant is 4.8x 0-3 oz-in./rad/s.

10.9The torque (Kt) constant is 0.06 oz-in./v and damping constant (Dm) is 7.16 oz-in./rad/s.

10.10The parallel capacitance required to make the winding appear purely resistive is 16.6 microfarads.

10.11The total head developed is 19.03 ft.

10.12Rotary pumps function by continuously producing reducedpressure cavities on the suction side, which fills with fluid. The fluid is moved to the discharge side of the pump, where it is compressed and then discharged from the pump.

Chapter 11

11.1Some of the disadvantages of early centralized control computers were as follows: 1) very slow operating speed, 2) very small computer memory size (4K to 8K), 3) all programming had to be done in machine language, and 4) lack of programming experience by control vendors and users.

11.2The process data collected at level 1 is transferred to level 2. At this level, process operators and engineers use consoles with a keyboard, mouse, and video display to view and adjust the various processes being controlled and monitored by the system. At level 2, process and control engineers implement advanced control functions and strategies, and operations management members perform advanced data collection and analysis on process information. The various plant management systems—such as inventory management and control, billing and invoicing, and

366 Measurement and Control Basics

statistical quality control—exist at level 3. The highest level is used to provide extensive process and operations information to corporate management in large industrial plants.

11.3The functions and features of a typical DCS are control and monitoring, operations interface, and advanced applications software.

11.4The processor reads the inputs, executes logic as determined by the application program, performs calculations, and controls the outputs accordingly.

11.5The main purpose of the I/O system is to provide the physical connection between the process equipment and the PLC system.

11.6Some typical discrete input devices found in process industries are process switches for temperature, flow, and pressure.

11.7Some typical discrete output signals encountered in industrial applications are control relays, solenoid valves, and motor starters.

11.8Some typical analog signal values found in process control applications are 4 to 20-maDC current, 0 to 10 vDC, and 1 to 5 vDC.

11.9The difference between volatile and nonvolatile memory is that volatile memory will lose its programmed contents if all operating power is lost or removed. Nonvolatile memory will retain its data and program even if there is a complete loss of operating power.

11.10The common applications for personal computers in programmable controller systems are programming, graphical unit interfaces, and data collection.

11.11The personal computer is the most common device used to program PLCs.

11.12The three basic instructions used in ladder logic programs are the 1) normally open, 2) normally closed, and 3) coil output instructions.

11.13Power flow in a relay ladder diagram is the flow of electric current from the left side to the right side of a ladder rung.

11.14Logical power flow is obtained in a LAD program if there is logical continuity from the left side to the right side of a ladder logic rung.

11.15STL instruction statements have two basic structures. One, a statement made up of an instruction alone (for example, NOT) and another where the statement is made up of an instruction and an address.

Index

Absolute block temperature

185, 363

Absolute humidity

216, 218, 220

Absolute pressure

125

 

 

AC induction motors

300

 

 

AC motor

297, 300

 

 

 

Acid 204

 

 

 

 

 

 

 

Air bubbler system

153

 

 

Algorithm

54

 

 

 

 

 

 

Annubars

259

 

 

 

 

 

Anti-reset windup

21

 

 

 

Application software

318

 

 

Archimedes' principle

149

 

Armature

293

 

 

 

 

 

Armature current

293, 297

 

Armature speed

295

 

 

 

Armature-controlled motors

296

Artificial process control

1

 

Atmospheric pressure

118

 

Automatic process control

 

1

Beat frequency

 

266

 

 

 

Bellows pressure element

130

Bernoulli, Daniel

 

281

 

 

 

Bourdon tube

129

 

 

 

Boyle's law

123

 

 

 

 

 

Bubble tubes

213

 

 

 

 

Buoyancy force

150, 210

 

 

Callendar-Van Dusen equation 192 Capacitance 36

Capacitance probes 155–156 Capacitance-type pressure sensor 135 Capacitive circuits 156

Capacitor 36, 155

Carbon dioxide analyzers 234

 

Cascade control

49–51

 

Cascade controllers

51

 

Cavitation

285–287, 365

 

Celsius scale

172

 

 

Celsius, Anders

172

 

Centrifugal pump

 

303

 

Charles' law

 

124

 

 

 

Choked flow

287, 289

 

Circumferential piston pumps

305

Coefficient of linear expansion

177

Combustible gases

233

 

Combustibles

233

 

 

Concentric orifice plate 254

 

Conduction

 

44

 

 

 

Conductivity

201–202

 

cell

202

 

 

 

 

instruments

203

 

measurement

201

 

probes

159

 

 

 

Control

3

 

 

 

 

 

element

 

5

 

 

 

loop

7

 

 

 

 

 

Control valve

5, 14, 275

 

Control valve basics

275

 

Control winding

301

 

Controlled variables 2

 

Controller

4, 9, 28

 

 

Convection

44

 

 

 

Copper-constantan thermocouple 182 Coriolis mass flowmeters 269 Coulomb 36, 156

Critical pressure ratio 290

367

368 Measurement and Control Basics

Damped response

7

 

 

 

 

Damping constant

302

 

 

 

Davy, Sir Humphry

 

188

 

 

 

DC motor

293, 300

 

 

 

 

Dead time

11, 47–48, 61

 

 

 

Density

118, 208

 

 

 

 

 

Density measurement

212

 

 

Density-measuring element

214

 

Derivative action

21

 

 

 

 

Derivative time

23

 

 

 

 

Dew point

218, 220

 

 

 

 

Diaphragm

129

 

 

 

 

 

 

actuator

13

 

 

 

 

 

 

detectors

154

 

 

 

 

 

pumps

306

 

 

 

 

 

 

Dielectric constant

156, 158

 

Differential pressure

213, 244

 

Differential-pressure flowmeters 252

Differential-pressure measurement

214

Digital computers

313

 

 

 

Digital voltmeter (DVM)

182

 

Direct digital control

312

 

 

Direct-current (DC)

10

 

 

 

Discharge coefficients

255

 

 

Displacement meter

210

 

 

Displacer

147, 149–150, 210

 

Dissociation constant

204

 

 

Distributed control system (DCS)

315, 318

Disturbances

2

 

 

 

 

 

 

Dry-bulb temperature

218

 

Electric motor

292

 

 

 

 

 

Electrical ladder logic

311

 

 

Electrical systems

 

35

 

 

 

Electrolytes

201

 

 

 

 

 

 

Electromotive force (emf)

 

295

 

Equal percentage valve

277

 

Error area

9

 

 

 

 

 

 

 

Error function

7

 

 

 

 

 

 

Evaluation

3–4

 

 

 

 

 

 

Fahrenheit scale

172

 

 

 

 

Fahrenheit, Gabriel

171–172

 

Farad

36, 156

 

 

 

 

 

 

 

Faraday's number

207

 

 

 

Faraday’s law of induction

263

 

Feedback control loop

27, 30, 358

 

Feedforward control

52

 

 

 

Field current

293

 

 

 

 

 

Field magnet

293

 

 

 

 

 

Filled-system thermometer

175

 

Final control devices

275

 

 

First-order lag

32, 34, 39, 47

 

Flame ionization detectors

234

 

Flashing

285–287, 365

 

 

Float switches

165–166

 

Flow

 

 

 

 

 

 

 

 

coefficients

255

 

 

in a uniform pipe

244

 

nozzle

257

 

 

 

 

principles

241

 

 

 

Fluid

117

 

 

 

 

 

 

Fluid Controls Institute (FCI)

283, 364

Fluorescence analyzers

235

 

Gage pressure

125

 

 

 

Gain

54

 

 

 

 

 

 

 

Galileo

171

 

 

 

 

 

Gas analysis

221, 232

 

 

Gas law constant

207

 

 

Gear pumps

305

 

 

 

 

Glass gages

147

 

 

 

 

Glass rotameters

271

 

 

Gravitation constant

40

 

Gravity

119

 

 

 

 

 

Hand switches

10

 

 

 

Heat transmission

 

44

 

 

High recovery valve

289

 

Humidity 216

 

 

 

 

 

Humidity measurement

216, 218

Hydraulic press

 

121–122

 

Hydraulic resistance 40

 

Hydrocarbon analyzers

234

 

Hydrogen sulfide analyzers

236

Hydrogen-ion concentration

204

Hydrometer

209

 

 

 

 

Ideal fluid

241

 

 

 

 

 

Impedance

301

 

 

 

 

Impeller

304

 

 

 

 

 

Inductive reactance

301

 

Infrared analyzers

 

235

 

 

Instrument Society of America 313

Integral

 

 

 

 

 

 

 

action

17, 55

 

 

 

of absolute error multiplied by time

 

 

 

(ITAE)

57

 

time

18

 

 

 

 

 

Integrated circuits

 

315

 

 

International System of Units (SI) 118 International Temperature Scale (ITS) 173 Ionization constant 204

Ions 204

Iron-constantan thermocouple 184 Isothermal block 185, 187, 363

Kelvin temperature scale 172

Kinetic energy

 

242–243

 

Lag 11, 56

 

 

 

 

Laminar flow

39

 

 

Laplace transform method

34

Law of intermediate metals

186

Lead time 56

 

 

 

 

Level measurement

147

 

Level switches

 

165

 

 

Linear valve

277

 

 

Liquid systems

39

 

 

Low recovery valve

289

 

Lower explosive limit (LEL)

233

Magnetic flowmeters

263–264

Magnetic flux

295

 

 

Magnetic flux lines

299

 

Manipulated variables 2

 

Manometers

126–127

 

Manual reset

15

 

 

Measurement

3–4

 

 

Metal-film RTDs

189

 

Meter coefficient, turbine flowmeters 261 Metering pumps 306

Microfarad 156 Microprocessor-based controllers 316 Microprocessors 311, 315

Minimum integral of absolute error (IAE) 57 Minimum integral of square error (ISE) 57

Motor characteristic 296

 

Motors 275

 

 

Narrow bands

54

 

Natural process control

1

Nernst equation

207

 

Nitrogen oxide analyzers

235

Nuclear devices

214

 

Nutating-disk PD flowmeters 268

Offset 54

Ohm’s law 35, 38 One-quarter wave 61 On-off control 10–11

Open-tank pressure level sensor 152 Operations interface 318

Optical filters

237

 

Orifice plate

6, 254

 

Oval-gear PD flowmeters

268

Oxygen analyzers 232

 

Particulate measurements

232

Pascal's law

120

 

Pascal, Blaise

120

 

Pascals 118

 

 

 

 

 

 

 

 

 

 

 

Index

369

Perfect gas law

176

 

 

 

 

 

 

pH electrode systems

206

 

 

 

 

pH measurement

204

 

 

 

 

 

Phototube

237

 

 

 

 

 

 

 

 

Piezoelectric

134–135

 

 

 

 

 

 

crystal

168, 265

 

 

 

 

 

 

Piezoelectric-type sensor

134–135

 

Pitot tube

258

 

 

 

 

 

 

 

 

Platinum resistance temperature detector

188

Plunger pumps

306

 

 

 

 

 

 

Pneumatic pressure cell

131

 

 

 

Pneumatic pressure transmitters

131

 

Pneumatic signals

5

 

 

 

 

 

 

Positive-displacement flowmeters

267

 

Potential energy

242

 

 

 

 

 

 

Power factor

300

 

 

 

 

 

 

 

Pressure

117–118

 

 

 

 

 

 

differential

286

 

 

 

 

 

 

gages

128

 

 

 

 

 

 

 

 

measurement

117

 

 

 

 

 

profile

285

 

 

 

 

 

 

 

sensors

117

 

 

 

 

 

 

 

transmitters

131

 

 

 

 

 

 

Pressure-recovery characteristics

289

 

Process

3–4

 

 

 

 

 

 

 

 

 

computers

313

 

 

 

 

 

 

control computers

310

 

 

 

control concepts

9

 

 

 

 

 

controller

 

28

 

 

 

 

 

 

Process reaction curve

61–62

 

 

 

method

61

 

 

 

 

 

 

 

Process reaction rate

62

 

 

 

 

 

Programmable controllers

311

 

 

Programmable logic controller

310, 318

 

Progressing cavity pump

305–306

 

Proportional band (PB)

15, 54

 

 

 

Proportional control 12, 53

 

 

 

 

Proportional gain

15

 

 

 

 

 

 

Proportional sensitivity

54

 

 

 

 

Proportional-integral-derivative (PID)

 

control

56

 

 

 

 

 

 

 

 

 

Proportional-plus-derivative (PD) control

21

Proportional-plus-integral action

55

 

Proportional-plus-integral control

17

 

PSI (pounds per square inch)

5, 118

 

Psychrometer

 

219

 

 

 

 

 

 

Psychrometry

 

219

 

 

 

 

 

 

Pumps

275, 302

 

 

 

 

 

 

 

Quarter wave damping

61

 

 

 

 

Quick-opening valve

277

 

 

 

 

Radiation

44

 

 

 

 

 

 

 

 

 

Radiation-type instruments

161

 

 

370 Measurement and Control Basics

Ramo-Wooldridge

309

 

 

 

Rangeability

 

278

 

 

 

 

 

Rankine scale

 

172

 

 

 

 

 

Rankine, W. J. M. 172

 

 

 

Ratio control

51

 

 

 

 

 

Ratio control loop

52

 

 

 

 

Ratio controller

51

 

 

 

 

Reciprocating pumps

306

 

 

Relative humidity

216, 218–219

 

Reset

17

 

 

 

 

 

 

 

 

 

action

17, 55

 

 

 

 

 

rate

18

 

 

 

 

 

 

 

time

18

 

 

 

 

 

 

 

windup

 

20

 

 

 

 

 

Resistance

36

 

 

 

 

 

 

Resistance tape

158

 

 

 

 

Resistance temperature detectors 188

 

Resistance to temperature conversion

192

Resistivity

137, 202

 

 

 

 

Resistor

35

 

 

 

 

 

 

 

 

Rotameter

269–271

 

 

 

 

Rotary pumps

 

304, 365

 

 

 

Rotary-vane flowmeters

267

 

 

Rotating paddle level switches

166

 

RTD

190, 192

 

 

 

 

 

 

Seebeck voltage

179, 182

 

 

Seebeck, Thomas

179

 

 

 

 

Segmental orifice plate

 

255

 

 

Sensor

28

 

 

 

 

 

 

 

 

Servo applications

294

 

 

 

Set point

2, 4

 

 

 

 

 

 

 

Settling time

 

9

 

 

 

 

 

Siemens, Sir William

188

 

 

SO2 stack analyzer

236

 

 

 

Solenoid valves

10

 

 

 

 

Sorenson

205

 

 

 

 

 

 

Specific conductivity

202

 

 

Specific gravity

208, 210

 

 

Speed-torque curves

297

 

 

Stall condition

 

296

 

 

 

 

Stall torque

297

 

 

 

 

 

Steinhart-Hart equation

194

 

 

Strain gage

136

 

 

 

 

 

Strain gage pressure sensors 136, 139

 

Strong acid

205

 

 

 

 

 

Sulfur dioxide analyzers

235

 

 

Sulfur dioxide measurements

235

 

Sump pump

 

159

 

 

 

 

 

Supervisory data-monitoring system

310

System error

7

 

 

 

 

 

Tape float

147, 151

 

 

 

 

Temperature transmitter

10

 

 

Thermal capacitance

44, 46

Thermal capacity

44

 

 

Thermal resistance

45

 

 

Thermal system

44

 

 

 

Thermistor

187, 193–195

 

Thermocouple

179

 

 

 

J-type

184

 

 

 

 

T-type

182

 

 

 

 

Thermocouple tables

181

 

Thermodynamics

44

 

 

Thermoelectric circuit

179, 182

Thermometer

171

 

 

 

Three-mode control

56

 

Time constant

38, 61

 

 

Torque constant

296

 

 

Transducer

4, 28

 

 

 

 

Transmitter

28

 

 

 

 

Tuning capacitor

300

 

 

Tuning control loops

53

 

Turbine flowmeter

260–261

Turbulent flow

39

 

 

 

Two-phase induction motor

298

Ultimate gain (sensitivity)

58

Ultimate period

 

58, 60

 

 

Ultimate sensitivity

60

 

 

Ultrasonic flowmeters

265–266

Ultrasonic level sensors

161, 362

Ultrasonic level switches 168 Ultraviolet spectrophotometers 235 Underdamped response 7

U-tube manometer 128

Valve actuator 13 Valve characteristic 276

Valve sizing for liquids 278, 280 Valve-recovery characteristics 289 Valve-sizing coefficient 282, 284 Vapors 233

Variable inductance sensor 135

Variable-speed drive

303

Vena contracta

286, 289

Venturi tube

255

 

 

Vibrating cylinder

215

Vibrating single-tube

215

Vibrating twin-tube

215

Vibrating U-tube

215

Vibrating vane

215

 

Vibration method

215

Volts 36

Vortex shedding device 263

Weak acid 205

Weak base 205

Index 371

Wedge flow element

257

Weight density 150

 

Wet-bulb temperature

218

Wheatstone bridge circuit 190

Wide bands 54

Work 243

Ziegler-Nichols tuning method 58, 60–62, 64

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