ACTUATORS AND POSITIONERS OPERATION

ACTUATORS
Actuators provide the driving force that controls a valves position. They are also required to reliably perform the following:
 Move the valve ball, plug or stem to the required position.
 Hold the position against the forces of the flowstream.
 Close off the flow by applying sufficient force.
 Provide the required operation for full control, from fully open to fully closed.
 Operate the movement at the required speed.
1. Electromechanical
Using a motor through a gearbox, this type of actuator provides either reciprocating or rotary action depending on the type of
valve being used. A power screw is used to transfer the rotary action to linear or reciprocating action if applicable.
This type of actuator is suitable for applications requiring high torques. However, the movement is slower and may impede
system response. These actuators are limited in their control capability so they are seldom used in control applications.
Advantages. High thrust. Easily interfaced to control system.
Disadvantages. Large. More expensive than pneumatic. High power electrical source. Poor controllability.
2. Hydraulic
Simple hydraulics are used, where a piston is hydraulically driven and provides the necessary movement to position and control
the valve. Although a fast response is achieved in the stroke action, an external hydraulic supply is however required. As with
most hydraulic devices, they are suitable for very high loads.
Advantages. Fast response to control signals. High loads. Variable stroking speed and stiffness.
Disadvantages. Requires external hydraulic supply. Not spring loaded, generally not fail-safe.
3. Pneumatic – Piston
Piston actuators provide very long travel with a very high thrust. They are more compact than the spring and diaphragm but
do have increased stiffness. The increased stiffness is a result of the higher loading pressures due to the air/spring forces.
Springless piston actuators are available, but require a separate pneumatic system to provide a fail safe mode.
Advantages. Very long travel. High thrust. Compact size. Increased stiffness.
Disadvantages. Fail safe requires trip system.
4. Pneumatic - Spring and diaphragm
Spring and diaphragm actuators are very simple and reliable. The major advantage is the spring fail action that provides full
shutoff in the event that the pneumatic air supply fails. Depending on the construction, the fail mode can either move the stem
up or down. This provides fail-open or fail-closed operation.
Advantages. Fail safe operation.
Disadvantages. Actuator force must work against spring.
5. Solenoid
With the solenoid actuator, an electric current is applied to a solenoid coil which forces a metal plunger. The position of the
plunger is determined by the applied voltage.
Solenoid actuators give good control but are limited by thrust capability. They are more expensive than comparative pneumatic
actuators, but less expensive than electromechanical actuators.
Advantages. Electrically controlled, therefore interface directly. Less expensive than electromechanical actuators.
Disadvantages. Limited thrust. More expensive than pneumatics.

POSITIONERS
In applying a force to an actuator, there is no guarantee that the actuator is in the correct position. Positioners are used to
feedback position information and ensure that the valve is in the correct position regardless of the opposing forces.
For pneumatic control, the positioner attempts to put the valve into the correct position. The output of the control device is not
related to the input signal, but relies on the positioner to achieve the correct valve position.
Advantages. Assist in overcoming friction. Greater actuating pressures available.

VALVE BENCHSET AND STROKING

Benchset are the actual pressure ranges for travel of the actuator with no friction. These are the actual maximum and minimum
pressures that move the actuator from end to end of its range of operation. This is typically performed on the actuator before
it is mounted onto the valve.
Stroking is the pressure range for the operation with friction. Stroking takes into account the added pressure required to
overcome friction forces when the actuator is connected to the valve assembly.
The operational stroking range adds pressure and flow effects.

IMPACT ON THE OVERALL CONTROL LOOP

There are at least two concerns when integrating control valves into a control loop application.
 Response time of the control valve
 Error and control at low flow/shutoff
The response time of the control valve adds to the overall response time of the control loop. If there is too much of a ramp
delay on the valve then this can make control of the process quite sluggish.
Depending on the rangeability of the control valve, control can be difficult at low flow rates as the accuracy and resolution of
actuation is diminished. The problem arises when the valve is sized for a large flow rate with an associated large pipe diameter.
When low flow rates are required the valves do not have the physical capacity to control to the tolerances required.

FUTURE TECHNOLOGIES
Smart Valves
The microprocessor gives an instrument the ‘smarts’ to look at other information and calculate an optimum output for the
process.
Information that the device may monitor would be: Inlet pressure. Outlet pressure. Inlet temperature. Position of stem. Top and
bottom actuator pressure. Positioner signal.
Some of the functions that the smart instrument can perform are:
 Instrument signature.
 Local process control.
 Valve diagnostics.
 Process diagnostics.
 Configurable failure modes.