Valve positioners compare a control signal to a valve actuator's position and move the actuator

accordingly. They are used with both linear valves and rotary valves. Valve positioners are used
when the 0.2 to 1 bar pressure in the diaphragm chamber is not able to cope with friction and
high differential pressures.

Image Credit: Spirax Sarco

The positioner is fitted to the yoke of the actuator and is linked to the spindle of the actuator by a
feedback arm in order to monitor valve position. When a control signal differs from the valve
actuators position, the valve positioner sends the necessary power to move the actuator until the
correct position is reached. This uses a high air supply.

Positioners should be installed if the valve is intended for use in a control application.

Types of Valve Positioners

There are four basic types of valve positioners: pneumatic, electronic, electro-pneumatic, and
digital.
Pneumatic devices send and receive pneumatic signals. They are intrinsically safe and can
provide a large amount of force to close a valve.
o Single-acting or three-way pneumatic positioners send air to and exhaust air from
only one side of a single-acting valve actuator that is opposed by a range spring.
o Double-acting or four-way pneumatic positioners send and exhaust air from both
sides of the actuator.

Electric valve positioners send and receive electrical signals. There are three electric
actuation types: single-phase and three-phase alternating current (AC), and direct current
(DC) voltage.

Electro-pneumatic valve positioners convert current control signals to equivalent

pneumatic signals.

Digital or smart devices use a microprocessor to position the valve actuator and
monitor and record data. They are very accurate, use less air than analogue positioners,
and allow for online digital diagnostics.

Performance Specifications
Performance specifications for valve positioners vary by pneumatic input signal range, maximum
supply pressure, milliampere input signal range, split range, operating temperature, and output
action.

Pneumatic input signal range and maximum supply pressure are measured in pounds
per square inch (psi).

Split ranges commonly include 4 10 mA and 12 20 mA. Two-way, three-way, and

four-way splits are available.

There are three types of output actions: direct, reversible, and field reversible.
o Direct action devices increase the output signal as the input signal increases.
o Reversible action devices decrease the output signal as the input signal increases.
o Field reversible products can be switched between direct and reversible action.

Features
Intrinsically safe (IS) valve positioners do not produce sparks or other thermal effects that would
ignite a specified gas mixture. Devices that are made from stainless steel are used in corrosive or
high temperature environments. The valve positioner should also come with a valve position
indicator that suits the intended application.

Applications

Valve positioners differ in terms of applications, features, and approvals. Some products are
designed for automotive, aerospace, marine, medical, or military applications. Other products are
suitable for food processing or pharmaceutical applications. General-purpose devices are
commonly available.

Image Credit: Modeling and Control.com

Standards
Common approvals for valve positioners include marks from the Canadian Standards
Association (CSA) and Underwriters Laboratories (UL), an independent testing organization.
Additional standards can be found at the IHS standards store.

BS EN 60534-6-1 - Industrial-Process Control Valves Part 6: Mounting Details for

Attachment of Positioners to Control Valves Section 1: Positioner Mounting on Linear
Actuators

IEC 60534-6-2 - This part of IEC 60534 is intended to permit a variety of positioning
devices, which respond to a rotary motion, to be mounted on the actuator of a control
valve, either directly or by employing an intermediate mounting bracket.

Control valves
Control valves are valves used to control conditions such as flow, pressure, temperature, and
liquid level by fully or partially opening or closing in response to signals received from
controllers that compare a "setpoint" to a "process variable" whose value is provided by sensors
that monitor changes in such conditions.[1] Control Valve is also termed as the Final Control
Element.
The opening or closing of control valves is usually done automatically by electrical, hydraulic or
pneumatic actuators. Positioners are used to control the opening or closing of the actuator based
on electric, or pneumatic signals. These control signals, traditionally based on 3-15psi (0.21.0bar), more common now are 4-20mA signals for industry, 0-10V for HVAC systems, and the
introduction of "Smart" systems, HART, Fieldbus Foundation, and Profibus being the more
common protocols. Some of the control valves available are Reverse Double-Ported Globe-Style
Valve Body, Three-Way Valve with Balanced Valve Plug, Flanged Angle-Style Control Valve
Body, Valve Body with Cage-Style Trim, Balanced Valve Plug, and Soft Seat.[2]
A control valve consists of three main parts in which each part exist in several types and designs:

Valve's actuator

Valve's positioner

Valve's body

Contents

1 Types of control valve bodies

2 See also

3 References

4 External links

Types of control valve bodies

The most common and versatile types of control valves are sliding-stem globe and angle valves.
Their popularity derives from rugged construction and the many options available that make
them suitable for a variety of process applications, including severe service.[3] Control valve
bodies may be categorized as below:[4]

Globe valve with a manual hand-wheel

Globe control valve with pneumatic actuator and smart positioner

Types of control valves

Angle Valves
o

Cage-style valve bodies

DiskStack style valve bodies

Angle seat piston valves

Globe valves
o

Single-port valve bodies

Balanced-plug cage-style valve bodies

High capacity, cage-guided valve bodies

Port-guided single-port valve bodies

Double-ported valve bodies

Three-way valve bodies

Diaphragm Valves

Rotary valves

Butterfly valve bodies

V-notch ball control valve bodies

Eccentric-disk control valve bodies

Eccentric-plug control valve bodies

Sliding cylinder valves

o

Directional control valve

Spool valve

Piston valve

Air-operated valves
o

Air-operated valve

Relay valve

Air-operated pinch valve

Basics of Control Valve Positioners

A valve positioner is a device used to increase or decrease the air load
pressure driving the actuator of a control valve until the valve’s stem
reaches a position balanced to the output signal from the process variable
instrument controller. Positioners are generally mounted on the side-yoke or
top casing of the pneumatic actuator for linear-sliding-stem control valves
and at or near the end-of-shaft for rotary control valves. For either basic
design type, the valve positioner is connected mechanically to the valve stem
or valve shaft so that their position can be compared with the position
dictated by the controller. This mechanical feedback linkage work in such a
way that the process controller tells the positioner to “change”
position; the feedback linkage reports back to the positioner confirming that
a change in the position of the valve stem has occurred and gives a sense of
the magnitude of the change in position. Note that for continuous control over
the entire stroke of the valve, the use of positioners is usually necessary if
the valve position is required to closely follow the control signal.

However in some other applications where the feedback from the process is fast
and proportional to the valve opening, the position feedback used by the
positioner is not necessary and the valve can be driven directly by changing
its actuating force directly from the process controller.

Reasons for Using Valve Positioners

The reasons for use of the valve positioner are summarized below:
(1) Increase control system resolution i.e. fine control
(2) Facilitate operation when the higher number in the actuator bench-set
range is greater than 15psig. i.e. 10 - 30psig, 6 - 30psig
(3) Allow the use of characteristic cams in rotary valves
(4) Minimize valve stem packing friction effects and the resulting hysteresis,
particularly for high temperature packing materials such as graphite
(5) Negate flow-induced reactions to higher pressure drops. i.e compensate for
internal force imbalances
(6) Increased speed of response to a change in process; allows faster loading
and venting.
(7) Allow for split ranging. i.e. one controller for two valves
(8) To overcome seating friction in rotary valves
(9) Allow distances between controller and control valve
(10) Allow wide range of flow variation. i.e. operate at less than 10% travel
under normal conditions
(11) Allow increased usage of 4 - 20mA electronic signal
(12) Permit use of piston actuators with high instrument air supply pressures.

Types of Positioners
Positioners are available in three configurations:

1. Pneumatic Positioners
A 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. Note that the positioners used to articulate the
principle of valve positioners here are pneumatic.

2. Analog I/P Positioners

This positioner performs the same function as the pneumatic type, but
uses electrical current (usually 4-20 mA) instead of air as the input
signal.

3. Smart or Digital Positioners

Smart or digital positioners function very much as the analog I/P type
described above, however it differs in that the electronic signal
conversion is digital rather than analog. The digital products cover
three categories namely:
(a) Digital Non-Communicating: In this type, a current signal (4-20 mA)
is supplied to the positioner, which both powers the electronics and
controls the output.
(b) HART: This is the same as the digital non-communicating but is
capable of two-way digital communication over the same wires used for
the analog signal.
(c) Fieldbus: This type receives digitally based signals and positions
the valve using digital electronic circuitry coupled to mechanical
components. Here, an all-digital control signal replaces the analog
control signal. Additionally, two-way digital communication is possible
over the same wires. Fieldbus technologies benefit the end user by

enabling improved control architecture, product capability and reduced

wiring.

Typical Control Valve Configuration Without Positioner

The diagram above is for a linear sliding stem control valve without a
positioner. The valve has an actuator bench set of 5 - 13psig. As can be seen,
the valve configuration is air to open, fail close (ATO - FC). Once the
controller (PIC) outputs a control SIGNAL (designated SIG in the diagram
above), the signal acts as the load pressure on the diaphragm actuator of the
valve changes, resulting in valve stem travel. However, as can be seen from
the plot of Diaphragm/SIG Pressure against % percent travel of valve, there is
significant hysteresis throughout the valve stroke largely due to friction and
forces of inertia within the valve. It should be noted above that the
controller signal, SIG and the LOAD pressure on the actuator are the same flow
stream. Actuator air flows through the pneumatic controller and the
interconnecting tubing; air is vented through the controller. Due to the
absence of a valve positioner, no stem position feedback.

Typical Control Valve Configuration with Positioner

The diagram above is for a linear sliding stem control valve with a
positioner. The valve has an actuator bench set of 5 - 13psig. As can be seen,
the valve configuration is air to open, fail close (ATO -FC). Here also there

is a mechanical linkage between the valve stem and the positioner (V/P in the
diagram above) providing stem position feedback to the positioner. As can be
seen above, controller outputs a signal, SIG, which enters the positioner.
With a valve positioner, the SIG and LOAD streams are separate. Actuator air
flows through the valve positioner and its short interconnecting LOAD tubing.
The pneumatic controller (PIC) air flows through the tubing interconnecting
and the positioner, also called the SIG tubing.
The valve positioner provides stem position feedback to the control loop in
that a change in controller SIG output forces a change in positioner LOAD
output which results in a valve stem travel. The mechanical feedback linkage
then confirms that travel occurred. If no travel is fed back to the
positioner, positioner output will continue to change until stem travel is
confirmed. The plot of positioner output/LOAD versus % valve travel shows that
the hysteresis present is very small compared to the one without a valve
positioner. Typically valve hysteresis with positioners is 5% of valve stroke.

A positioner is a device put into a valve to ensure that it is at a correct position of opening as per
the control signal. An I/P converter only sends the opening/closing request to valve but can not
confirm its position.
Positioner senses the valve opening through a position feedback link connected to valve stem
which is its input signal. I/P converter output is its setpoint input. The difference between these
two is the error signal based on which the positioner positions the valve to correct position to
reduce error to zero. Hence positioner is nothing but a pneumatic feedback controller. Controlled
external supply air to positioner provides power to positioner to position a valve. Also positioner
is used in a valve when valve operating signal range is different from I/P converter output range.