Chapter 2

Pneumatic Control System

Pneumatic Control System (PCS), use compressed air to operate actuators, sensors,
relays & other control equipment. Pneumatic controls are powered by compressed air,
usually 15 to 20 psig pressure although higher pressures are occasionally used for
operating very large valves or dampers.
PCS differ from other control systems in several ways with some distinct advantages :
1- Pneumatic equipment is inherently proportional, as air pressure can be modulated
with infinite variation over the control range, but can be providing two-position
control when required.
2- Many control sequences and combination are possible with relatively simple
equipment. Because of their simplicity and low cost, and less maintenance cost.
3- Pneumatic equipment is suitable when explosion hazards exist.
4- The installed cost of the PCS and its materials may be lower

2-1 Basic Pneumatic Control System

A PCS is made up of the following elements: Compressed air supply system, mainline
distribution system, branch lines, sensors. controllers, actuators, final control elements.

Fig.2-1 Basic Pneumatic control system

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 As shown in figure 2-1,the air supply for a PCS must be carefully designed. It is
importance that the air be clean and dry, free from oil, dirt, and moisture. Thus it is
essential to use air dryers, oil separators, and high-efficiency filters. Even small amounts
of dirt, oil, or water can plug the very small air passages in modern commercial
pneumatic devices, rendering them useless.
2-2 Defintions:
 Direct-acting: A controller is direct-acting when an increase in the level of the sensor
signal (temperature, pressure, etc.) results in an increase in the level of the controller
output (in a pneumatic this would be an increase in output air pressure).
 Reverse-acting is the opposite of direct-acting; that is, an increase in the level of the
sensor signal results in a decrease in the level of the controller output
 Restrictor: is a basic component of a PCS and is used in all controllers. A restrictor is
usually a disc with a small hole inserted into an air line to restrict the amount of air flow.
The size of the restrictor varies with the application, but can have a hole as small as
o.oo3”.
 Nozzle-Flapper Assembly: (fig. 2-2) is the basic mechanism for controlling air pressure
to the branch line. Air supply to the nozzle escapes between the nozzle opening and the
flapper. At a given air supply pressure, the amount of air escaping is determined by how
tightly the flapper is held against the nozzle by sensing element such as bimetal.
The regulated branch line pressure, a restrictor is added to the nozzle-flapper assembly
(fig.2-3)
With this basic mechanism, all that is necessary to create a controller is too add a sensing
element to move the flapper as the measured variable ( e.g .. temperature, humidity,.etc )

Fig. 2-2 Nozzle Flapper assemblies Fig.2-3 Nozzle Flapper assemblies with Restrictor

 Pilot Bleed system (Amplifier Relay): is a means of increasing capacity as well as

reducing air consumption. The capacity amplifier that is a pilot bleed component that

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 maintains the branch line pressure at the same value as the pilot pressure but provides
greater airflow capacity (fig.2-4)
If the pilot pressure from the nozzle increases, the pilot chamber diaphragm is forced
down, which open the feed valve and allows main air into the branch chamber. When the
pilot pressure decrease, the pilot chamber diaphragm rises, closing the feed valve. If the
pilot chamber diaphragm raises enough, it lifts the bleed valve off the feed valve disc,
allowing air to escape from the branch chamber through the vent thus increasing the
branch line pressure.

Fig. 2-4 Pilot Bleed System with amplifier Relay

 Signal Amplifier: the addition of the capacity amplifier, pneumatic systems also use a
signal amplifier. The signal amplifier must be very sensitive and accurate, because the
input signal from the sensor may change as little as, 0.06 psi per degree Fahrenheit.
Fig. 2.5 shows the amplifier as used in a direct acting, single input proportional
controller. The signal amplifier is a three-stage proportional comparator. In a direct-
acting controller, the sensor input feeds chamber P2, where the proportional comparator
unit compares it to the set point pressure in chamber P3 generated by the set point
pressure reducing valve (PRV). For reverse action, inputs to the chambers P2 and P3 are
reversed.
Branch line pressure is piped to the chamber P4 to provide negative feedback. The
output from the proportional band potentiometer setting is connected to chamber P1 to
provide positive feedback

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 Fig 2-5 Single amplifier in a proportional amplifier. .

 Feed and Bleed System: this system of controlling branch line pressure is more complicated than the nozzle-
flapper assembly but uses less air. The system consists of a feed valve that supplies main air to the branch line,
and a bleed valve that exhausts air from the branch line (Fig. 2-6). Each valve consists of a ball rested on the top
of a tube. A spring valve is continually try to force the lever against the balls. A force applied by the sensing
element at the sensor input point is opposed by the set point adjusted spring and lever. When the sensing element
pushes down on the lever, the lever pivots on the bleed ball and allows the feed ball to rise, which allows main air
into the chamber. If the sensing element reduces its force, the other end of the lever rises and pivots on the feed
ball, and the bleed ball rises to exhaust air from the system.

Fig. 2-6 Feed and Bleed System

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 3-3 Sensing Elements:
 Temperature Sensing Elements
o bimetal element
o vapor-filled bellows
o Bulb and capillary elements
 Pressure Sensing Elements
o Diaphragms
o Bellows
o bourdon tubes
 Humidity-Sensing Elements
Hygroscopic materials, which change size in response to changes in humidity

Bimetal Sensing Element. Rod-and-Tube Insertion Sensor.

Remote-Bulb Temperature Sensor.

Fig 2-7 Some type of sensing sensors

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2-4 Relays and Switches:
Relays are used in control circuits between controller and control devices to perform
function beyond the capacity of the controllers. Relays typically have diaphragm logic
construction ( Fig. 2-8). They are used to amplify, reverse, average, select, and switch
controller outputs before being sent to valve and damper actuators, by diverting air between
various system components such as valves actuators, thermostats, and damper actuators.
The controlling pressure is connected at the pilot port (P), and pressures to be switched
are connected at the normally connected port (O) or the normally disconnected port (X).
The operating point of the relay is set by adjusting the spring pressure at the top of the relay.
When the pressure at the pilot port reaches the relay operating point, it pushes up on the
diaphragm in the control chamber and connects pressure on the normally disconnected port
(X) to the common port as shown. If the pilot pressure falls below the relay set point, the
diaphragm moves down, blocks the normally disconnected (X) port, and connects the
normally connected port (O) to the common port.

Fig. 2-8 Typical Switching Relay.

2-5 Throttling Range Adjustment:

A controller must always have some means to adjust the throttling range (proportional
band). In a pneumatic controller, the throttling range is the change at the sensor required to
change the branch line pressure 70 kPa. The set point is usually at the center of the
throttling range. For example, if the throttling range of a temperature controller is 2 kelvins
and the set point is 22°C, the branch line pressure is 20 kPa at 21°C, 55 kPa at 22°C, and
90 kPa at 23°C for a direct acting controller.
In all pneumatic systems except the sensor-controller system, the throttling range is
adjusted by changing the effective length of a lever arm. In Figure 2-9, the throttling range
is changed by moving the contact point between the bimetal and the flapper.

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 Fig 2-9 Temperature Controller with Bimetal Sensing Element

2-6 Questions and Answers

1- What are the advantages of pneumatic control systems?
2- Draw a schematic diagram of the basic Pneumatic control system, showing the main elements?
3- Define the following: Direct-acting, Reverse-acting, Restrictor, Transducer, Pneumatic control relay,
pneumatic actuator,
4- Rationalize the following:
 The transducers are necessary with pneumatic control system?
 The sensing bulb of bulb and capillary sensor, may be only a few inches long, as used in
a pipe or a tank, or it may be as longer?
 The compressed air used in pneumatic control system must be dry and clean?
 Elements made of hygroscopic material is used in humidity sensors?
5- Draw showing the main parts and explain the operation of the Noon - Bleed System to control branch
line pressure in pneumatic control systems?
6- Draw showing the main parts and explain briefly the operation of the Bleed type controller System to
control branch line pressure in pneumatic control systems?
7- Draw a diagram showing the main parts of Pneumatic proportional relay controller, pilot-bleed type?
8- Draw a diagram showing the Pilot Bleed System with amplifier Relay?
9- Draw a diagram showing the main parts of a single-input, sensor-controlling system in a balanced
condition?
10- Draw and explain the operation of bulb and capillary sensor?
11- Draw a diagram showing pneumatic Reversing relay?
12- Draw a diagram showing pneumatic Relay: output is proportional to the difference between two
signals?
13- Draw a diagram showing pneumatic Relay: output is proportional to the difference between two
signals?

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