Chapter 4

Control Valve Accessories

This chapter offers information on digital valve controllers, analog positioners, boosters, and other control valve accessories.

(usually 4-20 mA) instead of air as the input signal. 3. DigitalAlthough this positioner functions very much as the Analog I/P described above, it differs in that the electronic signal conversion is digital rather than analog. The digital products cover three categories. D Digital Non-CommunicatingA current signal (4-20 mA) is supplied to the positioner, which both powers the electronics and controls the output. D HARTThis is the same as the digital non-communicating but is also capable of two-way digital communication over the same wires used for the analog signal. D FieldbusThis type receives digitally based signals and positions the valve using digital electronic circuitry coupled to mechanical components. An all-digital control signal re65

Positioners
Pneumatically operated valves depend on a positioner to take an input signal from a process controller and convert it to valve travel. These instruments are available in three configurations: 1. PneumaticA pneumatic signal (usually 3-15 psig) is supplied to the positioner. The positioner translates this to a required valve position and supplies the valve actuator with the required air pressure to move the valve to the correct position. 2. Analog I/PThis positioner performs the same function as the one above, but uses electrical current

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places the analog control signal. Additionally, two-way digital communication is possible over the same wires. The shift in field communications technology towards a fieldbus technology benefit the end user by enabling improved control architecture, product capability and reduced wiring. A shift toward the use of analog I/P positioners, one instrument, instead of a combination of pneumatic positioner and transducer, two instruments, has been taking place for many years. This shift results from lower installed cost for the single instrument approach and the gradual acceptance of electronic instruments for valve service. This trend combines with a move toward HART and fieldbus products to change the instrument mix away from transducers, pneumatic positioners and to analog I/P positioners and digital valve controllers (figure 4-1). The ability to embed software commands into the memory of the device represents the real difference between digital and analog I/P segments. This allows automatic configuration and setup of the valve. Most importantly, it allows two-way communication for process, valve, and instrument diagnostics. A general trend moves toward higher positioner use on control valves because of greater use of DCS systems and customer focus on valve accuracy. Users purchase digital valve controllers for several reasons: D Reduced cost of loop commissioning, including installation and calibration. D Use of diagnostics to maintain loop performance levels. D Improved process control through reduced process variability. D Offset the decreasing mechanical skill base of instrument technicians.
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W6848/IL

Figure 4-1. Modern Control Valve Utilizing a Digital Valve Controller

Two aspects of digital valve controllers make them particularly attractive: D Automatic calibration and configuration. Considerable time savings are realized over traditional zero and spanning. D Valve diagnostics. Through the Distributed Control System (DCS), PC software tools, or handheld communicators, users can diagnose the health of the valve while it is in the line. FIELDVUER instruments enable new diagnostic capabilities that can be accessed remotely. This single element requires a look at the potential impact of the technology as it applies to control valves.

Chapter 4. Control Valve Accessories

OUTPUT TO DIAPHRAGM RELAY

INSTRUMENT

BELLOWS SUPPLY ACTUATOR VALVE STEM CONNECTION FEEDBACK AXIS PIVOT NOZZLE FLAPPER

DIRECT ACTION QUADRANT INPUT AXIS CAM

22A7965A A2453-2 / IL

BEAM

REVERSE ACTION QUADRANT

Figure 4-2. Positioner Schematic for Diaphragm Actuator

In the past, an in-plant person, with the aid of the FlowScannert system, could diagnose the health of a valve through a series of off-line tests. Customers used to replacing valves on a routine basis, now are better able to detect, before removing the valve, the physical condition of the valve. Digital instruments allow an extension of this service with added enhancements: D It is now possible to diagnose the health of a valve remotely. D On-line diagnostics enable predictive maintenance. These two additional elements are extremely important to the user. The remote capability allows monitoring valves and reporting to the user on the condition of their asset. Those who make, supply, and service valves for a living now assist the customer in

the diagnosis of valve condition to a level never before possible. Predictive maintenance offers additional savings for the customer. It is now possible to see the performance of the valve as it operates. Watching performance decline over time enables the user to predict when replacement is necessary. It can even indicate the need for a different product, such as a sliding stem valve in the place of a butterfly valve.

Other Control Valve Accessories

Figure 4-5 illustrates a top-mounted handwheel for a direct-acting diaphragm actuator. This unit can be used as an adjustable travel stop to limit travel in the upward direction or to manually close push-down-to-close valves. Figure 4-6 illustrates a top-mounted handwheel for a reverse-acting dia67

Chapter 4. Control Valve Accessories

A1304/IL

Figure 4-3. Positioner Schematic for Piston Actuator

INPUT SIGNAL DIAPHRAGMS EXHAUST PORT EXHAUST BYPASS RESTRICTION ADJUSTING SCREW BYPASS RESTRICTION

SUPPLY PORT SUPPLY OUTPUT TO ACTUATOR

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Figure 4-4. Volume Booster 68

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W2078

W03681/IL

Figure 4-5. Top-Mounted Handwheel for Direct-Acting Diaphragm Actuator

A7095/IL

W2078/IL

Figure 4-7. Cam-Operated Limit Switches

W03691/IL

Figure 4-6. Top-Mounted Handwheel for Reverse-Acting Diaphragm Actuator

phragm actuator. This unit can be used as an adjustable travel stop to limit travel in the downward direction or to manually close push-down-toopen valves.

relays, or alarms. The cam-operated type (figure 4-7) is typically used with two to four individual switches operated by movement of the valve stem. An assembly that mounts on the side of the actuator houses the switches. Each switch adjusts individually and can be supplied for either alternating current or direct current systems. Other styles of valve-mounted limit switches are also available.

Solenoid Valve Manifold

The actuator type and the desired failsafe operation determine the selection of the proper solenoid valve (figure 4-8). The solenoids can be used on double-acting pistons or single-acting diaphragm actuators.
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Limit Switches
Limit switches operate discrete inputs to a distributed control system, signal lights, small solenoid valves, electric

Chapter 4. Control Valve Accessories

mon reduced-air-supply pressures are 20, 35 and 60 psig. The regulator mounts integrally to the positioner, or nipple-mounts or bolts to the actuator.

Pneumatic Lock-Up Systems

Pneumatic lock-up systems (figure 4-10) are used with control valves to lock in existing actuator loading pressure in the event of supply pressure failure. These devices can be used with volume tanks to move the valve to the fully open or closed position on loss of pneumatic air supply. Normal operation resumes automatically with restored supply pressure. Functionally similar arrangements are available for control valves using diaphragm actuators.

W7007/IL

Figure 4-8. Solenoid Valve

Fail-Safe Systems for Piston Actuators

In these fail-safe systems (figure 4-11), the actuator piston moves to the top or bottom of the cylinder when supply pressure falls below a pre-determined value. The volume tank, charged with supply pressure, provides loading pressure for the actuator piston when supply pressure fails, thus moving the piston to the desired position. Automatic operation resumes, and the volume tank is recharged when supply pressure is restored to normal.

Electro-Pneumatic Transducers
Figure 4-12 illustrates an electropneumatic transducer. The transducer receives a direct current input signal and uses a torque motor, nozzle-flapper, and pneumatic relay to convert the electric signal to a proportional pneumatic output signal. Nozzle pressure operates the relay and is piped to the torque motor feedback bellows to provide a comparison between input signal and nozzle pressure. As shown, the transducer can be mounted directly on a control valve and operate the valve without need for additional boosters or positioners.

W0047/IL

Figure 4-9. Supply Pressure Regulator with Filter and Moisture Trap

Supply Pressure Regulator

Supply pressure regulators (figure 4-9), commonly called airsets, reduce plant air supply to valve positioners and other control equipment. Com70

Chapter 4. Control Valve Accessories

35A6998-C A2285-4/IL

Figure 4-10. Lock-Up System Schematic for Piston Actuator

35A6996-C A2283-4/IL

Figure 4-11. Typical Schematic of a Fail-Safe System

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FILTER REGULATOR

ELECTRO PNEUMATIC TRANSDUCER

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Figure 4-12. Electro-Pneumatic Transducer with Supply Regulator for Operation of Diaphragm-Actuated Control Valve

Figure 4-13. Electro-Pneumatic Positioner on Diaphragm Actuator

Electro-Pneumatic Valve Positioners

Electro-pneumatic positioners (figure 4-13) are used in electronic control loops to operate pneumatic diaphragm control valve actuators. The positioner receives a 4 to 20 mA DC input signal, and uses an I/P converter, nozzle-flapper, and pneumatic relay to convert the input signal to a pneumatic output signal. The output signal is applied directly to the actuator diaphragm, producing valve plug position that is proportional to the input signal. Valve plug position is mechanically fed back to the torque comparison of plug position and input signal. Split-range operation capability can provide full travel of the actuator with only a portion of the input signal range.
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PC Diagnostic Software
PC diagnostic software provides a consistent, easy to use interface to every field instrument within a plant. For the first time, a single resource can be used to communicate and analyze field electronic smart devices such as pressure xmtrs, flow xmtrs, etc., not pneumatic positioners, boosters. Users can benefit from reduced training requirements and reduced software expense. A single purchase provides the configuration environment for all products. Products and services are available that were not possible with stand-alone applications. The integrated product suite makes higher level applications and services possible.