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3x800MW NTPC KUDGI

Introduction to pneumatic
actuator elements and
preliminary trouble shooting

Prepared By:

Durgesh Verma
and Aditya Pandey

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Common Elements of
pneumatic actuators
1.Trip Valve
2. Air Lock valve/ Switching valve
3.Volume Booster
4.Positioners
5.AFR( Air Filter cum Regulator)
6.SOVs
7.Speed Controller/Throttle valve
8.Limit Switches
9.Volume Tank 2
 1. Trip Valve
Pressuresensing trip valves, are for control
applications where a specific valve/actuator action is
required when supply pressure falls below a specific
point.
When supply pressure falls below the trip point, the
trip valve cause the actuator to fail up, lock in the last
position, or fail down.
When the supply pressure rises above the trip point,
the trip valve automatically resets, allowing the system
to return to normal operation.
Trip valves are used with all types of piston actuators.

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Typical Fisher 377 Trip Valve

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 Simplified Sectional View of Trip Valve

Pressure adjusting screw

UPPER
VALVE DIAPHRAGM
PLUG
SPRING EXHAUST
PORT
SUPPLY
CONNECTION RESTRICTION
LOWER
DIAPHRAGM
PORT D PORT A

PORT E PORT B

PLUG
ASSEMBLIES
FIG.1 PORT F PORT C 6
 Principle of Operation of 377 Trip Valve in Fail down mode

MAIN SPRING

VENT

SUPPLY
PRESSURE

PORT D
PORT A

PORT E
PORT B

PORT C

PORT F
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FIG 1.1
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 In normal operation supply pressure loads the upper diaphragm of the trip valve.
The valve plug spring keeps the exhaust port closed.
Supply pressure also loads the lower diaphragm through the restriction, causing the
plug assemblies to move down and isolate ports C and F while connecting port A to B
and port D to E.
Normal actuator control pressure from the control device is applied to the top of the
cylinder through ports A and B and to the bottom of the cylinder through ports D
and E.
A volume tank is charged to the maximum supply pressure through a check valve.
The check valve maintains maximum supply pressure in the volume tank if the
supply pressure drops. When the supply pressure falls below the trip point, the
exhaust port opens venting the supply pressure that is loading The lower diaphragm.
This causes the upper ports of the plug assemblies to close and disconnect normal
pressure from the control device to the actuator.
Volume tank pressure is then applied through ports C and B to the top of the
actuator cylinder, while pressure in the bottom of the actuator cylinder is vented
through ports E and F. The pressure imbalance created forces the actuator piston
down
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 Principle of Operation of 377 Trip Valve in Fail Up mode

MAIN SPRING

VENT

SUPPLY
PRESSURE

PORT D PORT A

PORT E
PORT B

PORT C
PORT F

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 The failup mode of operation is similar to the faildown mode of
operation except that the connections to port C and F are reversed.
When supply pressure falls below the trip point, the top of the
actuator cylinder vents, and volume tank pressure loads the bottom of
the actuator cylinder. The pressure imbalance created forces the
actuator piston up.

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 Principle of operation 377 Trip valve in the
lockinlastposition mode.

MAIN SPRING

VENT

SUPPLY
PRESSURE

PORT D PORT A

PORT E
PORT B

PORT C
PORT F

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 When supply pressure falls below the trip point, the exhaust port
opens venting supply pressure from the lower diaphragm.
This causes the upper ports of the plug assemblies to close and the
lower ports to open. Because ports C and F are plugged, no pressure
change occurs on either side of the actuator piston and the piston is
pressurelocked in position. No volume tank is necessary in this mode.
When supply pressure is restored, the plug assemblies move back into
the normal operating position.
Supply pressure from the control device is applied to the actuator
through ports A and B and ports D and E.

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2. Switching valve/Air Lock valve
Air Switching/ Air lock valves are for control
applications where a specific valve/actuator action is
required when supply pressure falls below a specific
point.
When supply pressure falls below the set point, the
switching valve cause the actuator to lock in the last
position.
When the supply pressure rises above the trip point,
the trip valve automatically resets, allowing the system
to return to normal operation.
Trip valves are used with all types of single acting
diaphragm actuators.
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Typical Fisher 167D Switching Valve

THREE-WAY SWITCHING VALVE

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Typical Fisher 167D Switching Valve
internals

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Principle of Operation of 167DA Switching Valve
Control pressure enters the switching valves
through Port D and registers under the diaphragm.

Control pressure overcomes the spring force and the

diaphragm, and raises the valve plug, closing port C and
opening port B of the Type 167DA three-way switching
valve.
Type 167DA construction provides flow from path A to B.

If, either intentionally or through pneumatic failure, the

control pressure drops below the spring force, the
diaphragm and valve plug move downward, opening port C
and closing port B of the Type 167DA three-way switching
valve. In this condition both constructions provide a flow
path from port A to port C.
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 3.Volume Boosters
Volume Booster is a high volume amplifier used to increase
the operating speed of the actuator, preventing the time lags,
in the systems where controller & the control valve are
separated by extremely long piping runs.

Volume Booster receives the low volume signal from the

controller & transmits from an auxiliary supply a high volume
signal to the control valve actuator.

Volume Booster is specially recommended for the use with

large capacity diaphragm actuator.

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FISHER VBL VOLUME BOOSTER

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FISHER VOLUME BOOSTER SECTIONAL VIEW

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Principle of operation

A large, sudden change in the input signal causes a

pressure differential to exist between the input signal
and the output of the booster. When this occurs, the
diaphragms move to open either the supply port or the
exhaust port, whichever action is required to reduce the
pressure differential.

The port remains open until the difference between the

booster input and output pressures returns to within the
dead band limits of the booster.

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INSTALLATION OF VOLUME BOOSTER WITH
PISTON ACTUATORS AND DIAPHRAGM ACTUATOR
4.Positioners
A position controller, which is mechanically connected
to a moving part of a actuator, and automatically adjusts
its output pressure to the actuator in order to maintain a
desired position through in built I to P converter.
I/P Converter , converts 4-20 mA signal from controller
to .2 to 1.0 Kg/cm2 pneumatic signal. Click here
When positioner get in put signal ,it compares it with
stem position and output is generated and signal boosted
sufficiently to operate the valve.
The positioner can be used to modify the action of the
valve (reversing positioner) through its program
parameters.
Positioner, double acting: A positioner with two
outputs, suited to a double acting actuator.
Positioner, single acting: A positioner with one output,
suited to a spring opposed actuator. 23
CONTROL VALVE SMART POSITIONERS FROM
DIFFERENT MANUFACTURES

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MECHANICAL MOUNTING OF A POSITIONER

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The maximum rotation angle for position feedback is 60 when installed on
linear actuators and 120 on part-turn actuators. The minimum angle is
always 25.
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IMPORTANT (NOTE)
After mounting the unit check whether the operating range for
the actuator matches the sensor range on the positioner.
Positioner feedback link should match parallel with respect to
the actuator 50% scale.
Positioner must be supplied with instrument air that is free
of oil, water and dust.
Pressure above 6 bar (90 psi) can damage the positioner.
For Calibration
After Positioner proper mounting check s and positioners 24VDC supply
available, it can be Calibrated by referring to their instruction manual.
A Quick/auto calibration mode is available in every smart positioner.
Please Note the minimum and maximum set point mA from DCS is
3.80mA and 20.50mA for proper operation of the positioner.

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5.AFR( Air Filter cum Regulator)
Air leaving a compressor is hot, dirty, and wetwhich
can damage and shorten the life of downstream
equipment, such as valves and cylinders. Before air can be
used it needs to be filtered, regulated and lubricated.
An air line filter cleans compressed air. It strains the
air and traps solid particles (dust, dirt, rust) and
separates liquids (water, oil) entrained in the
compressed air. Filters are installed in the air line upstream
of regulators, lubricators, directional control valves, and air
driven devices such as cylinders and air motors.
Air line filters remove contaminants from pneumatic
systems, preventing damage to equipment and
reducing production losses due to contaminant related
downtime.
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AIR FILTER REGULATORS

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Sectional view of a typical AFR

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Pressure adjusting knob

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6. Speed Controllers/Regulators
Speed Controller/regulators valves are
used to reduce the rate of flow in a section
of a pneumatic circuit, resulting in a
slower/faster actuator speed. Unlike a
Needle Valve, a Flow Control Valve
regulates air flow in only one direction,
allowing free flow in the opposite
direction.

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Speed controllers/Throttle valves

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Cross sectional View

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 7.SOVs
A solenoid valve is an electromagnetic operated valve. The
valve is controlled by an electric current through a solenoid. In
the case of a two-port valve the flow is switched on or off; in
the case of a three-port valve, the outflow is switched between
the two outlet ports.

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8.Limit Switches
A limit switch is an electromechanical device that
consists of an actuator mechanically linked to a set
of contacts. When an object comes into contact with
the actuator, the device operates the contacts to
make or break an electrical connection.

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9.Volume Tanks
The air failure position of a valve is not always its failsafe
position.
So volume tanks supply a reserve air for actuating the double
acting
piston valve in its actual safe position for safety of process and
equipment's.

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Common problems & their trouble shooting
Control valve not Operating ?
Primary/Basic visual checks:-
CVs manual operated handwheel must be in its neutral position i.e.
matches with its neutral pointer and wheel moves freely. Click here
Air supply pressure/set pressure must be adequate and with in the
minimum and maximum range of required pressure for the valve. It can
be regulated/adjusted in AFR knob. Click here Click here
Positioners feedback shaft along with its lever must be in coupled
condition with the valve position lever link. Click here
There should be no air leakage from air tubings/diaphragm. It can cause
pressure drop which tends to valve oscillations/hunting.
Positioner display must be in power ON condition and if It has display
with ERROR /ALARM then refer to the positioner configuration
parameter instruction manual for diagnostic. error
handlings/Alarms.( For ABB positioner From page No-76 to 83)
Command set point mAs should match for required position. Click here
At last check positioners internal program parameters should match as
per the data sheet . For e.g. Valve Action , feedback action etc. It can be
matched with the help of respective company positioner manual i.e.
ABB , BRAY CONTROLS , SIEMENS, YTC, SMC etc. click here
 FAQs
Q. Trip valve/Air lock valve not working/acting ?
A. If this kind of problem persists then below checks should be taken care
:-
Check the set and reset pressure of the trip valve and air lock valve
mentioned on their name plate/data sheet . Click here
Some times it is observed that minimum supply pressure is found less
than the set point for acting the Trip valve/air lock valve that The air
pressure set point of Trip valve 377 for respective valve is mentioned in
their data sheet
If the pressure set point is found miss match with the data sheet then
it can be adjusted through adjusting screw provided on the top . Click
here

Q. Speed Controller/Throttle valve setting for actuator required

travel time achievement ?
A. Speed controller or throttle valve has only control for the amount of air
draining. By closing the knob amount of air drain will be slow thus causing
the actuator to move slow and opening the knob will cause air drain
quick hence actuator movement will increase.
Q. Control valve is hunting/oscillation problem ?
A. Air leakage between the actuator and positioner can cause the valve hunting.
This is the primary check . If it is okay, then switch the positioner to local
operating mode and set it to a position of approx. 50% using the local push
button . If the position is stable then auto stroke one time and save the
parameters.
B. If still hunting is there then check the air volume booster bypass restriction
adjusting screw while the actuator is hunting and adjust the screw in
clockwise direction. Sometimes hunting can occur if bypass adjusting screw
is loose or improper adjustment. Click here
C. If still hunting persists then either friction of valve is much or the
DEADBAND time is need to be adjusted . For example. In ABB positioner it
can adjusted in program parameter 7.7 and 7.8.

Q. AUTO CALIBRATION Failure?

A. The common reason for AUTO CALIBRATION failure is positioner mounting
angle is outside the recommended range. i.e . +30 deg to -30 deg for linear
actuators and +60 deg to -60 deg for rotary actuators. The positioner feedback
lever should match parallel when the valve is in 50% position. Click here , click
here
THANK YOU
Valve Neutral Positions

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Valve L-linkage with positioner feedback lever

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 Standard set points to positioners

Standard Set points for air to open valves/Direct action Standard Set points for air to close valves/Reverse action

Set point mAmp's Valve Position Set point mAmp's Valve Position

4 0% 20 0%

8 25% 16 25%

12 50% 12 50%

16 75% 8 75%

20 100% 4 100%

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Name plates

Set and reset press

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ABB Positioner Program Parameters

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Pressure set points in Guages

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I/P Converter

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