Food process control

and
Instrumentation

FSPT3132

Teklehaimanot
1 06/24/2025
 Chapter One :Introduction
The meaning and importance of process
control

The meaning of instrumentation

Method of measurement

Design steps of a control system

Instruments of control sysystem

 Process
Process is defined as the changing or
refining of raw materials that pass through
or remain in a liquid, gaseous, or slurry state
to create end products.

A process is broadly defined as an operation

that uses resources to transform inputs. It is
the resource that provides the energy into
outputs into the process for the
transformation to occur .
 Process control

PC
A field of engineering dealing with ways and
means by which conditions of processes are b
rought to and maintained at desired
and undesirable conditions are avoided as m
uch as possible

 is the organization of activities with the

purpose of:
 Maintaining certain variables of a process
(such as temperatures, pressures,
concentrations, flow rates etc.) within
specified limits or
 PC
The purpose of process control is :
 To Reduce the variability , Wastage and
Production costs

 By improving the efficiency of processing in

the final products so that legislative
requirements and consumers’
expectations of product quality and safety
are met.
 PC
The objectives of process control are, among
others:
 To enhance the reliability of the process
 To improve process safety
 To increase production
 To reduce the proportion of production
units which do not meet the specifications
 To improve process economics, by
reducing production cost.
 PC

The concept of ‘ control ’ is not limited to

industrial processes.
Any process, be it biological, social,
economical, political or military, usually
features some sort of control mechanism.
Control may be manual or automatic.
 PC

Process control
 The automated control of a process.
Process control is used extensively in
 Oil refining,
 Chemical processing,
 Electrical generation
 The food and beverage industries
where the creation of a product is based on a
continuous series of processes being applied
to raw materials.
 Objectives of process control
Manufacturers control the production
process for three reasons:
 Reduce variability
 Increase efficiency
 Ensure safety
Major objectives of process control are
satisfying requirements with regard to:
 Product specifications
 Safety
 Operational constraints
 Environmental regulations
 Economy/ Optimization
 Objectives of process control

Product specification:
 A plant should produce its product with the

desired quality and quantity/specification.

To do this various parameters that affect

the quantity and quality of the production

should be controlled.
 Objectives of process control

Safety
 Safety is a basic requirement for the

people inside and around a process plant.

 To attain safety requirements such

parameters as pressure, temperature,
concentration, etc. should be regulated.
 Objectives of process control

Operational constraints
The various types of equipments used in a

process plant have constraints inherent to

their operation.
 Example tanks have limited volume and

unless they are controlled they will

overflow or go dry.
Control system are used to satisfy these

operational constraints.
 Objectives of process control

Environmental Regulations:
 Environmental concerns are growing and
there are regulations that specify such
parameters as the concentration,
temperature and flow rates of effluents.

Hence, control systems are used to satisfy

these requirements too.
 Objectives of process control
Economic requirements/ Optimization:
For almost every plant cost and profit are
crucial issues.

Both are highly affected by the operation

condition of the plant which in its turn
depends on the quality and quantity of the
raw materials as well as quality and quantity
of the product that the plant plans to
produce at a given production period
.
This requires certain parameters to be
adjusted every time. Process control play
 To achieve control Objectives

We achieve the control objective by

 Suppressing the effect of external

disturbances
 Ensuring stability
 Optimization
 Parameters to be controlled

 Liquid level

 Density

 Temperature
 pH (acidity or alkalinity)
 Pressure
 Mass

 Flow rate

 Conductivity

 Concentration
 Set Point

Set point is a value for a process variable

that is desired to be maintained.

For example, if a process temperature needs

to kept within 5 °C of 100 °C, then the set
point is 100 °C.

 A temperature sensor can be used to help

maintain the temperature at set point.
 variables in control system
 Figure 1
 variables in a control system

Controlled variables
These are the independent variables of a process
and can be defined as parameters of the
process indicating product quality or the
operating conditions of the process (quantify the
performance the given system)

It also called output, factor (variable)that is

caused by a system

In a food extrusion process figure (1),the

controlled variables are the product quality
attributes such as density,color,moisture
content ,etc.
 variables in a control system
Manipulated variables
 These are the dependent variables of the process used
to cause change in the process.
 It is called control input and is defined as a factor
(variable )used to modify system behaviour.
 These input variables are adjusted dynamically to keep
the controlled variables at their set-points.
 Therefore inputs are variables that cause or simulate a
change in system behaviour .
 Extruder variables (Figure 1) that have a significant
effect on the process variables or product attributes ,and
can be readily changed or manipulated during
processing ,are considered manipulative variables for
control purposes
 These manipulated variables include screw speed ,barrel
temperature ,feed-rate ,and water rate
 variables in a control system
Disturbance variables
 A signal that tends to adversely affect the state of
the systems that value of the system’s output and
can be classified by internal or external
disturbances.
 An internal disturbances referred to us those
disturbances originating within the system while,
 An external disturbances originates outside the
system
 In a food extruder (figure 1),screw wear is an
internal disturbances and raw materials variability is
an example of external disturbances to the system
in control.
 These are also called "load" variables and represent
input variables that can cause the controlled
 Example
Consider the simple case of a thermostated,
electrically heated laboratory water bath
( Figure 2 ).
 Example
 Assume that the control objective is to maintain the
temperature of the bath at 37°C

 We set the thermostat knob of the bath to 37°C and we

turn the heater on

 A thermometer measures the temperature of the water

 When the temperature of the water exceeds 37°C, the

thermostat turns off the heater automatically

 The temperature of the water drops

 When the temperature drops below 37°C, the thermostat

turns on the heater automatically, and so on.
 Example
Define a number of basic elements in this simple
case:
 The water bath is the process
 The water temperature is the controlled variable
 The electric current is the manipulated variable. In
our case it can have only two values: on or off
 37°C is the set point. It may be stored in the
thermostat under various forms (digital data, position
of a cursor, tension of a spring etc.)
 The thermometer is the sensor or the measuring
element
 It measures the temperature and sends to the
thermostat a signal carrying information about the
temperature ( measurement signal )
 The difference between the set point and the actual
 Example
The thermostat is the controller
 It compares the measured value (signal from the
sensor) with the set point stored in its memory
and calculates the error.
If the error is outside a preset range (known as
the differential band) , it issues a signal
( correction signal) to the electric switch.
The signal, which can be an electric current, a
mechanical force or a digital signal, causes the
switch to close or to open
The switch is the actuator , also known as the
final control element
 Any factor capable of making the system deviate
from the set point is a disturbance
 Example
 The path of the signals forms a loop known
as the control loop ( Figure 3 ).

A control loop may be open or closed. In our

case, the control loop is a closed loop
Basic control flow diagram
 The meaning of instrumentation
Instrumentation is defined as "the art and
science of measurement and control".
 Instrumentation can be used to refer to the
field in which instrument technicians and
engineers work in, or it can refer to the
available methods and use of instruments.

Instruments are devices which are used to

measure attributes of physical systems.

The variable measured can include practically

any measurable variable related to the
physical sciences
Measurements
 Measurements
In order that the results of measurement are
meaningful, the basic requirements are:

(i) The standard used for comparison

purposes must be accurately defined and
should be commonly acceptable,

(ii) The standard must be of the same

character as the measurand (the unknown
quantity or the quantity under
measurement).
 Measurements
iii) The apparatus used and the method
adopted for the purposes of comparison
must be provable.
 Measurements
The methods of measurement may be
broadly classified into two categories:
 Direct Methods.

 In-Direct Methods.
 Measurements
Direct Methods.
In these methods, the unknown quantity
(measurand) is directly compared against a
standard.

The result is expressed as a numerical

number and a unit.

It is quite common for the measurement

of physical quantities like length, mass
and time.
 Methods of Measurements

Measurements by direct methods are not

always possible, feasible and practicable.

These methods in most of the cases, are

inaccurate because they involve human

factors.

They are also less sensitive. Hence direct

 Methods of Measurements
Indirect Methods
In engineering applications Measurement
Systems are used.

These measurement systems use indirect

methods for measurement purposes.

A measurement system consists of a

transducing element which converts the
quantity to be measured into an analogous
signal.
 Methods of Measurements
The analogous signal is then processed by
some intermediate means and is then fed to
the end devices which present the results of
the measurement.
 Major control problems
 Design of control systems

 Stability analysis

 Tuning of controllers

 Maintenance of control systems

 Design of control systems
Design of control systems involves
 Defining the control objective
 Identifying the variables
o Input variable and output variable
 Selecting the control configuration
o Feedback, feed forward,
 Selecting the manipulated variable
 Selecting the controller type
 Design of control systems

Feed tank Condenser

Comp. A
C
W
Reflux
C drum
W
Top
Distillation produc
Feed
column t
preheater

Reactor Steam
CW
Feed tank Reboiler
Food Processing Instrumentation and
Comp. B Bottom
Control [FSPT 32152]
cooler Bottom P.
 Design of control systems

P
Condenser C
Feed tank
Comp. A CW

FC LC

CW TC

TC
Distillation
LC Feed
column
preheater
FC

LC Steam
Reactor
CW
Feed tank TC Reboiler
Food Processing Instrumentation and
Comp. B Bottom
Control [FSPT 32152]
cooler Bottom P.
 Stability analysis
 Some processes have unbounded response for
bounded change in input/ load, such processes are
known as unstable.
 Unstability is a very serious control problem
 Both controlled and uncontrolled process may
exhibit instability under certain circumstances.
 Unstability may be even caused in some systems
due to controllers:
Stability analysis

150 m3/hr

FC

150
m3/hr
 Stability analysis

170 m3/hr

• Load change of
20m3/hr (sustained)
• The liquid level
increases
FC
continuously until it
finally overflows

150 m3/hr
Stability Analysis
Response of unstable processes

Output
variable

Time
Stability Analysis

Food Processing Instrumentation and

Control [FSPT 32152]
 Tuning of controllers

 Controllers have parameters to be adjusted that will influence their

performance
 Adjusting the parameters of controllers to achieve optimum response
for a controlled process is known as TUNING.
 Effective tuning requires understanding of
o Dynamics of the process
o Dynamics of the control system elements
o The type of controller and its setting
 Examples: Stirred tank heaters

 Temperature
Control
 Level control
 Examples : Heat Exchangers

Temperature Control
 Example : Distillation column

Cooling
Reflux water

Feed
Distillate

Steam
Bottom
Product
Food Processing Instrumentation and
Control [FSPT 32152]
 Questions?
What is a process control?
What are the functions of a control system of
a control loop?
What are the objectives of PC?
How do we achieve these control objectives?
List the major control problems.
State the steps of designing of a control
system
What are the causes of unstability of a
process?
Assumptions: in Food Processing Industries
and Beverage Industries
 Classification of Variables

The variables( Flow rates, temperature,

pressure, etc) for control purpose are
classified into :
 Input variables : Indicate the effect of the
surrounding on the process.
 Output variables: Indicate the effect of the process

on the surroundings

Note that: The human operator and an

automatic control system are part of the
surrounding
 Classification of Variables: Gravity
Flow Tank

Input Variables: Fi,(F) Fi

Output Variables: V, F
V

F
 Classification of Variables:Stirred Tank
Heater

Input Variables: Fi, Ti, Fst , Fi,

(F) Ti

Output Variables: V, F, T V, T

Fst

Food Processing Instrumentation and

Control
 Classification of Variables:

Fi, CAi,
Ti Fc, Tc

V, T

Fc, Tci F, CA,T

Input Variables: CAi, Fi, Ti, Tci, Fc,

(F)
Output Variables: CA, T, F,
TCO,V
Food Processing Instrumentation and
Control
 Classification of Variables

Input variables are classified into

1. Manipulated ( Or adjustable) variables
Inputs that are freely adjusted by human
operator or control mechanism
2. Disturbances (loads)
Input that are not the result of adjustment by
human operator or control mechanism

Output Variables and disturbance are further

classified into measured and unmeasured

Food Processing Instrumentation and

Control
 Classification of Variables

Measured (d) Unmeasured (d’)

… …
..
Manipulated
.. Processing .
.
variable(m)
System
Measured
Outputs (y)

…
Unmeasured Output
Food Processing Instrumentation and
Control (z)
 Designing Steps of the Control System

The steps involved in the design of control

systems
1. Defining the control objective
2. Identifying and classifying
variables
3. Selecting the control
configuration
4. Selecting the manipulated
variable
5. Identifying the appropriate
controller type or control law
 Defining control objective
Before going to any design step the
control objective should be clearly
stated.

It can be stated in such terms as

To Maintain the temperature at…0C
To stabilize the unstable process at…
C
0

To maximize the profit

 Identifying and classifying
variables
Once the objective is defined all variables
that affect the control process should be
identified and classified into:
Input variables
Output variable
 Selecting The Control Configuration
The most common types of configurations
are
Feedback control configuration
Feedforward Control Configuration
Inferential Control Configuration

Depending on the number of controlled

outputs and manipulated variables we can
distinguish between
MIMO / Multiple Input Multiple Output
SISO / Single Input and Single Output
 Feedback control configuration

Disturbance
… measured
Output (Y)
Manipulated Process
variable(m)

Unmeasured Output
(z)

Controller
Food Processing Instrumentation and
Control [FSPT 32152]
 Inferential control configuration

Disturbance
…
Measured
Output
Manipulated Process
variable(m)

Unmeasured Output
(Controlled Variable)

Controller Estimator
Food Processing Instrumentation and
Control [FSPT 32152]
 Feed forward control configuration

Disturbance

Controller
Measured
Output
Manipulated Process
variable(m)

Unmeasured Output
(z)

Food Processing Instrumentation and

Control [FSPT 32152]
 Selecting the Manipulated Variable
-The choice of the appropriate manipulated
variable greatly determines the effectiveness of
the control system
-In general the manipulated variable:
• Should have direct and strong impact
• Should be simple to manipulate
-Flow rates can be manipulated easily with a
control valve
Study the response of the process for
Identifying the appropriate controller type/ Evaluation
assumed changes in set point
assumed changes in load/ Disturbances
best controller result in a closed loop
response that is
 Stable
 Fast
 With minimum oscillation
 Minimum overshot
 Short settling time

Food Processing Instrumentation and

Control [FSPT 32152]
 Example 1.4: Designing control system for a stirred
tank heater

Objective
To maintain the outlet temperature
at 400C and the liquid level at 4.5m 
0.1m, Fi,
or To=600C and h= 4.5m  0.1m
Variables Ti
Input variable: Fi, Ti
Output variables: Fo, To, h h
Manipulated variable
Fst, and Fo

Fo , To
Configuration
Feedback
Fst
Food Processing Instrumentation and
Control [FSPT 32152]
 Designing control system for a stirred tank
heater
Level
sensor

h=4.5m
Temperatur (Set
e Sensor point)

Controlle
T=600C Q r
(Set
Controller
point)

Food Processing Instrumentation and

Control [FSPT 32152]
 Selecting the appropriate controller
The job of the controller is to compare the
process signal from the sensor with the set point
and to send an appropriate signal to the control
valve.

There are three basic types of controllers that

are conventionally used for continuous feedback
control:
 Proportional / P
 Proportional Integral/ PI
 Proportional Integral Derivative/ PID
Selecting the appropriate
controller

The details of construction and principles of

operation vary from manufacturer to
manufacturer from pneumatic to electronic
devices, but their basic functions are the
same.
The main question at this stage, then, is
deciding which controller type does satisfy
the specified control objectives?

Food Processing Instrumentation and

Control [FSPT 32152]
Selecting the appropriate
controller

To choose the appropriate controller we

need to determine the quality of the
response of the uncontrolled process and
the controlled process (with each type of
controller) for representative load
changes (disturbances) and compare the
result. This will help us to determine:
 Whether the response is improved or
deteriorated when controller is used.
 If it is improved, which controller gives robust
(the best type) of response?

Food Processing Instrumentation and

Control [FSPT 32152]
Selecting the appropriate
controller

How shall I generate the response with and

without controller?

There are two general approaches

 The experimental approach
 The model approach/ Mathematical models
Selecting the appropriate
controller

The experimental approach

Advantages
If it could be done sufficiently, the decision will be
more precise hence more reliable.
Disadvantages
Very costly
Time and effort consuming
In some cases, not safe
Equipment is not available, if at design stage
Controllers are not available to carry out the closed
loop response (They are not yet selected and
bought)
Food Processing Instrumentation and
Control [FSPT 32152]
 Selecting the appropriate
controller
Mathematical Model
Advantage
Cheaper
Consumes less time and effort
Safe (no real experiment)
No equipment is required ( both the
process and the control system can
be modeled)
Disadvantage
Because of absence of accurate
information and technical data, in some
cases the reliability is limited.
 Selecting the appropriate
controller
How is the experiment carried out?
Example: the stirred tank heater
Case 1: Without controller
Adjust all the variables ( temperatures, flow
rates,liquid level) to the design condition
Create a disturbance,i.e., change the inlet
flow rate from the design point, say increase
it by one unit.
Measure the level and outlet temperature
with time
And study the response
 Selecting the appropriate
controller

The result of the response may be represented by

graph
Without controller

6.5 600c
m
level
540C
4.5 Time
m Temp.
Time disturbance
disturbance is caused
is caused
Time Time

Food Processing Instrumentation and

Control [FSPT 32152]
 Selecting the appropriate
controller

With P controllers

level
600c
590C
4.6
m
4.5 Time
m Temp.
Time disturbance
disturbance is caused
is caused
Time Time

Food Processing Instrumentation and

Control [FSPT 32152]
 Selecting the appropriate
controller

With PI controllers
controller
level
600c
590C

4.5 Time
m Temp.
Time disturbance
disturbance is caused
is caused
Time Time

Food Processing Instrumentation and

Control [FSPT 32152]
 Selecting the appropriate
controller

With PID controllers

controller
level
600c
590C

4.5 Time
m Temp.
Time disturbance
disturbance is caused
is caused
Time Time

Food Processing Instrumentation and

Control [FSPT 32152]
 Selecting the appropriate
controller

Such comparison may, theoretically, lead to the choice of the

best controller.
However, in practical cases the number of experiments will
be even greater than what we can assume in the mentioned
case because the above experiment is assumed to be carried
out at some given controller settings.
What about in other controller settings?
Hence the number of experiments required will be so big that
the cost, time and effort spent will not be affordable.
Therefore the mathematical model is inevitable in most
practical cases.

Food Processing Instrumentation and

Control [FSPT 32152]
 Process Control Instruments
Every automatic control configuration
requires:
Sensors
Transmitters
Controller
Final control element
 Process Control Instruments

Sensors
sensing devices are the first element in the control loop to measure
In all
the process variable, they are also called primary elements.
configuration whether manual or automatic
measurement is essential.
 In Feedback we measure output variables
 In feedforward we measure disturbances
 Inferential control configuration we measure
secondary measurements
The instruments used to measure these variables are
knownFood
asProcessing
sensors or simply
Instrumentation and measuring instruments.
Control [32152]
Sensors
Temperature and flow are the most
frequently measured variables in the
present day process industries.

The main reason is that many physical

phenomena are affected by it.

Temperature is also used to infer

other process variables.

Food Processing Instrumentation and

Control [32152]
Sensors
Factors Affecting Sensor Selection
Accuracy:- conformity with or nearness to the
true value of a quantity being measured.
Precision:-The repeatability of the readings
taken of the same value by the same
instrument.
Resolution:- The smallest change in the input
signal, which can be detected by the instrument.
Sensitivity :-The measure of the change in
output caused per unit change in input.

Food Processing Instrumentation and

Control [32152]
Sensors
Common Sensors
Temperature Sensors
Liquid level sensors
Pressure Sensors
Flow Sensors
Concentration Sensors

Food Processing Instrumentation and

Control [32152]
 Temperature Sensors
Temperature sensors classes
I. Expansion thermometers
 Liquid in glass
 Solid expansion thermometers ( bimetallic)
 Filled system thermometers
Gas –filled
Liquid –filled
Vapor filled
Temperature Sensors
II. Resistance –sensitive devices
 Resistance thermometers
 Thermistors

III. Thermocouples
IV. Non contact methods
 Optical pyrometers
 Radiation pyrometers
 Infrared techniques

Food Processing Instrumentation and

Control [32152]
 Thermocouples
Thermocouples:- The most popular
temperature sensors for control purpose.

Principle of Operation:- An electric current

flows in a continuous circuit of two different
metallic wires if the two junctions are at
different temperatures.
Thermocouples

Food Processing Instrumentation and

Control [32152]
Thermocouples
Pros’
 Low cost
 Wide range. (-262 to 27600C)
 Reasonably short response time.
 Reasonable repeatability and accuracy.

Food Processing Instrumentation and

Control [32152]
Thermocouples
Cons
Low sensitivity
Requires a known reference
temperature
Non linear response

Food Processing Instrumentation and

Control [32152]
Pressure Sensors
Pressure Sensors
Bourdon-tube elements
Bellow elements
Diaphragm elements
Strain gauges

Food Processing Instrumentation and

Control [32152]
Liquid level Sensors
Liquid Level Sensors
Float – actuated devices
Differential pressure Devices
Air bubbler

Food Processing Instrumentation and

Control [32152]
Flow sensors
Flow Sensors
Orifice meter
Magnetic flow meter
Turbine meter

Food Processing Instrumentation and

Control [32152]
Concentration Sensors
Concentration Sensors
Gas Chromatographs
Spectroscopic analyzer

Food Processing Instrumentation and

Control [32152]
Transmitters and Transducers
Types of transmission signals
Pneumatic (3-15 psig)
Electrical or electronic (4-20mA), (1-5V)(0-
10V)
Digital or discrete signal

Transducers :- devices to change one type of

signal to another
I/P- current to pneumatic transducers
E/P- Voltage to pneumatic transducers

Food Processing Instrumentation and

Control [32152]
The Final Control Element
 The final control element is the hardware
element which alters the value of the
manipulated variable in response to the
output signal from the controller or direct
manual manipulation.

 The most frequently used final control

element is the control valve.

 Other final control elements include

 relay switches (for on–off control)
 variable speed pumps
The Final Control Element
The Control Valve
 A control valves change the manipulated variable by
changing it’s opening which in its turn changes the
resistance to flow and, thus, the flow itself.
 Flow regulation by throttling is what control valves
actually do.
 In automatic control installations, it normally consists of
two parts.
 The actuator, which translates the output signal
from the controller into an action force
 The body, which alters the flow rate of the
manipulated variable to the required amount
 The Final Control Element

The most important aspects of a control valve are:

 Action of the valve
 Size
 Valve Characteristics

Action of The Valve

 Action of the valve is the flow position of the valve
when the signal from the controller (pneumatic or
electrical signal) fails.
In case of such a failure there are two most common valve
actions:
 Completely Open: Fail Open(FO)/ Air to Close(AO)
 Completely closed: Fail Closed/Air to Open
The Final Control Element

Air Air

Fail Open/ FO Fail Closed/ FC

(Air to Close)/ AC (Air to Open)/ AO
The Control Valve
When to use FO and when to use FC?
A proper analysis is necessary, usually the
safety condition determines!
Example
Cooling water in a reactor is mostly FO to
avoid heat accumulation and following danger?

If steam/ or oil for burner is the manipulated

variable usually it is safer to close it in
emergency situations hence FC/ AO is
appropriate.
 The Control Valve
Control valve characteristics
 The valve characteristic is the relationship between
the stem position of the valve and the flow rate of
the manipulated variable.

 Valve characteristics are classified into

 Inherent characteristics
 Effective characteristics

 The inherent characteristics is the characteristics

obtained when the valve is tested at the design
condition with constant pressure drop across the
valve.
The Control Valve
 The effective characteristics is the actual
relationship between the stem position and
the flow when the valve is applied to some
particular control system.
 The inherent flow characteristic is the only
convenient form for catalogue.
 The valves get their inherent characteristics from
the shape of the seat and plug of the valve
 The common inherent flow characteristics used are
 Linear trim valves
 Equal percentage trim valves
 Quick opening plugs
The Control Valve

Quick
Linear Equal opening
percentag
e
 The Control Valve
Linear trim
 The flow rate is linearly related to the stem position at
constant pressure drop
 F(x)=kx, where F is flow rate and x is the stem position

Equal percentage trim

Equal increments of stem motion produce equal percentage
changes
Quick opening
The relationship cannot be expressed mathematically. These
type of valves are usually cheaper.
The Control Valve
Selection procedure: General guideline
Use quick opening
For simple processes such as level control ,
temperature control of large liquid volumes,
and pressure control where valve
characteristics are relatively unimportant
The Control Valve
Use linear trim
When the pressure drop over the control
valve is fairly constant and a linear
relationship exists between the controlled
variable and the flow rate.
Use Equal percentage
When linear relationship does not exists
between the controlled variable and the
flow rate.
The Control Valve
 The transfer function of final control element
is second order, however in most cases they
have very quick dynamics in closed loop
transfer function as compared to the other
elements in the loop, that it is negligible
therefore is replaced by a gain.
 Control Valve Sizing

 Valves are sized so that there is a reasonable balance

between effective control action and the operating cost
Small valves are preferable from control point of
view
Large valves are preferable from operating cost
point of view/ cause less pressure drop

 Valve sizing is
carried out by calculating the valve
coefficient Cv and choosing the corresponding size
from manufacturer’s catalog.

Food Processing Instrumentation and

Control [32152]
 Control Valve Sizing

Determination of the valve coefficient Cv

Liquids
Q 
Where
C V

f ( x)  PV
Q = Design flow rate in gallon per
minute[gpm]
 = Specific gravity of the liquid
Pv = Design pressure drop across the valve
f(x) = % of maximum flow
Food Processing Instrumentation and
Control [32152]
Valve sizing

Q (design flow rate):

This is usually taken larger than the flow
rate at steady state condition (required
flow rate). In different literatures it is
taken care of in different
ways:1) Calculate the fully open flow rate by
multiplying the required flow rate by a factor
>1. In this case f(x)=1 in Equation 1.
Q=2Qrequired

Food Processing Instrumentation and

Control [32152]
Valve sizing
2) Take Qrequired to be the same as some
percentage of the maximum flow for example
Q= Qrequired but f(x)<1 usually f(x)=0.5.

Pv/ Design pressure drop

Large pressure drop is an economic loss and
small pressure drop leads to ineffective control
system, in general, a balanced value is taken

Pv equal to 25% Ptotal or 10 psi whichever is

greater

Food Processing Instrumentation and

Control [32152]