MAINTENANCE EXCELLENCE

Control Valves Operation & Maintenance

MGF
Feb 2016
Prepared by : Abdul Mateen (Instrument Specialist)
 Index

• Types of Actuators
• Introduction to Control Valve
• Control Valve Design
• Principle of Operation
• Control Valve Maintenance
• Control Valve Troubleshooting
• Positioner Design & Operation
Types of Actuator

Actuator Types

Pneumatic Hydraulic Electric Manual

Actuator Family
Pneumatic Actuators
Control Valve
Introduction to Control Valve

• One of the most common final control elements in industrial

control systems is the control valve.
• A “control valve” works to restrict the flow of fluid through
a pipe at the command of an automated signal, such as the
signal from a loop controller or logic device (such as a
PLC).
• Some control valve designs are intended for discrete
(on/off) control of fluid flow, while others are designed to
throttle fluid flow somewhere between fully open and fully
closed (shut), inclusive. The electrical equivalent of an
on/off valve is a switch, while the electrical equivalent of a
throttling valve is a variable resistor.
Control valve

• Control valves are widely used in industry

• The valves control the fluid in a pipe by varying the size of
the passage through which the fluid flows

• A common control valve consists of two distinct parts:

a) Actuator
b) Valve Body
 Actuator

• The valve actuator provides the force needed to physically

move a restrictor (in the valve body) to vary fluid flow
• The actuator consist of a diaphragm (made of rubber or
neoprene) and a spring.
• A pneumatic air signal
from the controller enters
the housing at the top
of the actuator
 Valve body

• The valve body is the housing that provides:

• Inlet and outlet connections
• A moveable restrictor that is in contact with the fluid and
varies fluid flow as the restrictor opens and closes a port
Control Valve Seat
 Control Valve Parts

Actuator

Yoke
Positioner

Actuator Stem
Signal Cable
Travel Indicator
Stem Connector
Valve Stem

Valve Body
Control Valve Parts

Actuator Spring
Positioner

Diaphragm plate

Bonnet
Valve Plug

Flange
Principle of Operation

• When the pressure of the control signal increases, it pushes

the diaphragm downward against the tension of the spring.
• The diaphragm moves until it creates an equal but opposing
force against the spring.

• At this position, the motion stops, and the plug and valve
stem to which the diaphragm is connected are in the
balance state.
• When there is no air pressure, the valve stem is pushed
upward by the spring,
Principle of Operation

• When there is the standard maximum 15 PSI pressure, the

valve stem is forced downward

• There is corresponding plug position for each different

pressure of a controller signal between 3-15 PSI

• This type of valve is capable of exerting large forces.

• The amount of force depends on the size of the diaphragm

and how much air is applied to it.
Principle of Operation

• For example, if the 15 PSI maximum pressure of a standard

pneumatic air signal is applied to a diaphragm that has a
diameter of 10 inches, the actuator provides a force of
1,177.5 pounds to move the valve, based on the formula
Control Valve Design
Principle of Operation

• The actuator is made up of two diaphragm cases, a rolling

diaphragm and springs.

• The lower diaphragm case is permanently fixed to the yoke

which allows the direct attachment of either a pneumatic or
electro pneumatic positioner or a limit switch.

• The signal pressure creates a force at the diaphragm

surface which is balanced by the springs (6) arranged in the
actuator.
Principle of Operation

• The number of springs and their compression determine the

bench range (signal pressure range)

• The stem connector (16) connects the actuator stem (2)

with the plug stem of the valve.
Control Valve Action
Control Valve Accessories

Actuator
Accessories

Limit
Regulator Positioner SOV Relay
Switch
Control Valve Maintenance
Adjusting the travel stop

• (with Type 3277 in special version only)

• The travel stop can be adjusted upwards
or downwards to 50 % of the travel.

Downward travel stop (actuator stem extends)

1. Undo the lock nut (34) and unscrew
the cap (33).
2. Undo the lock nut (31) and adjust the
nut (32) to set required travel stop.
3. Tighten the lock nut (31) again.
Adjusting the travel stop

Upward travel stop (actuator stem retracts)

1. Undo the lock nut (34) and adjust the cap (33) to set the
required travel stop.
2. Tighten the lock nut (34) again.
Maintenance Safety

• Ensure all the Safety Precautions are taken

• Use authorized personnel to service the valve.
• Never stick fingers into valve ports.
• Never touch the shaft of the valve whilst it is working.
• Always release fluid pressure from valve and piping before
disassembling the valve.
• Never touch hot valve or piping, if possible.
• Alternatively use protective gloves.
Dismantling valve form line

Following steps taken to dismantle valve from process line

1. Shut off line pressure

2. Shut off air supply
3. Shut off control power and disconnect connecting lines
4. Dismantle positioner (Accessories) if existent
5. Loosen flange connection
6. Detach flange housing connection
7. Remove Valve form line
Replacing the Diaphragm
Replacing the Diaphragm

1. Remove the diaphragm plate (7) together with

diaphragm (8) and actuator stem (2) from the
diaphragm case Depending on the actuator version,
proceed as follows:
2. For the 120 cm² version, undo nut (1) and remove the
diaphragm plate (7) (or collar nut in 355 cm² version). Pull
the diaphragm (8) off the diaphragm plate (7) (not
necessary with Type 3277-5 and Type 3277 with 355 cm²
as the diaphragm is held in place by the metal plate
Replacing the Diaphragm

3. Stretch the new diaphragm onto the diaphragm plate.

Fit the hose clamp evenly into the groove intended for it
and tighten with maximum 6 to 7 Nm.
4. Reassemble actuator.
Replacing the Stem seal

1. Remove the diaphragm plate (7) together with the

actuator stem (2) from the diaphragm case
2. Coat the new stem seal (12) with lubricant/sealant
(order no. 8152-0043) and insert it.
3. If necessary, replace the dry bearing (12.1) and wiper
(13) with new ones as well.
4. Reassemble the actuator
Type 3725 Positioner Design & Operation
Type 3725 Positioner Design & Operation
Type 3725 Positioner Design & Operation

• The electro pneumatic positioner is mounted on pneumatic

control valves and is used to assign the valve position
(controlled variable x) to the control signal (reference
variable w).

• The positioner compares the electric control signal of a

control system to the travel or opening angle of the control
valve and issues a signal pressure (output variable y) for the
pneumatic actuator.
Type 3725 Positioner Design & Operation

The positioner mainly consists of the following components

1) Anisotropic magneto resistive (AMR) sensor (2)
2) Analog i/p converter (6) with a downstream air capacity booster (7)
3) Electronics unit with microcontroller (4)
• The travel or opening angle is measured by the pick-up
lever connected to a magnet and a non-contact AMR
sensor (2) installed in the positioner and the downstream
electronics.
• The motion of the pick-up lever causes the direction of the
magnetic field to change. This change is sensed by the
AMR sensor.
Type 3725 Positioner Design & Operation

• The electronics unit determines the current valve position

or opening angle from this information.

• The position of the valve is transmitted to the

microcontroller (4) over its A/D converter (3).

• The PD control algorithm in the microprocessor compares

this actual position to the 4 to 20 mA control signal
(reference variable) after it has been converted by the A/D
converter (3).
Type 3725 Positioner Design & Operation

• In case of a system deviation, the activation of the i/p

converter (6) is changed so that the actuator of the control
valve (1) is pressurized or vented accordingly over the
downstream booster (7).

• The supply air is supplied to the booster and the pressure

regulator (8).
• The output signal pressure supplied by the booster can be
limited to 2.4 bar by software.
• The volume restriction Q (10) is used to optimize the
positioner by adapting it to the actuator size.
Technical Data
Technical Data
Operating Controls
Operating Controls

• Three capacitive keys and a LCD are used to operate the

positioner

• Touch or to select a parameter code (P0 to P20).

• Then touch to confirm the selected code.
Display Icons

• Icons assigned to certain Display Meaning

codes and functions are ESC Cancel

Err Error
indicated on the display. LOW w too low

• The bar elements indicate the MAN Manual mode

MAX Maximum range
system deviation that depends RST Reset
on the sign (+/–) and the INIT Initialization

value. ON/OFF Activated/deactivated

ZERO Zero calibration
Enable Configuration

• Before changing parameter settings, configuration must be

enabled first
• Enable Configuration by activating Code P19 as follows:

• Touch or until Code P19 appears.

• Touch to confirm the selected code. P19 blinks.
• Touch until OPEN appears on the display.
• Touch to unlock operation.
• If no settings are entered within three minutes, the enabled
configuration function becomes invalid.
Faults

• On the occurrence of a fault, the fault indication icon

appears at the bottom of the display.
• If the fault indication icon appears after a parameter code
setting has been changed,
• This indicates that this setting does not match the values
determined during initialization. See Code E1 in list
• Touch or past Code P0 or P20, the respective error
code E0 to E15 together with ERR appear on the display.
• Refer to the code list for the cause of the errors and the
recommended action.
Reset Error Codes

• The E0 and E8 error codes can be reset as follows:

• Touch or until the error code appears.
• Touch to confirm the error code.
ESC appears on the display.
• Touch or until RST appears.
• Touch six seconds long. 6-5-4-3-2-1-
is counted down on the display.
• Touch to reset the error.
• The reset procedure can be canceled by touching
when ESC appears.
Reset Error Codes

• The reset procedure can be canceled by touching

when ESC appears.
• A reset causes an initialization to be undone and all
parameters settings are reset to the default settings
• After the positioner has been reset, the display
automatically returns to status indication (P0).

• In this display, the angle is indicated in degrees relative to

the longitudinal axis.
Adjusting the volume Restriction Q

• The volume restriction Q serves to adapt the air output

capacity to the size of the actuator

• Actuators with a transit time < 1 s, e.g. linear actuators with

an effective area smaller than 240 cm², require a restricted
air flow rate.
Setting to MIN
• Actuators with a transit time ≥ 1 s do not require the air
flow rate to be restricted. Setting to MAX
• Intermediate settings are not permitted.
Adjusting the volume Restriction Q

Volume restriction

NOTICE
• The positioner needs to be initialized again after the
position of the restriction has been changed.
Initialization

• During initialization the positioner adapts itself optimally to

the friction conditions and the signal pressure required by
the control valve.
• The type and extent of self-adaptation depends on the
preset parameters.
• MAX is the default setting for the nominal range Code P4
• During the initialization process, the positioner
determines the travel range/angle of rotation of the valve
(from the CLOSED position to the other end position).
• Alternatively a different travel can be selected in CodeP4
Initialization

• Start initialization by activating Code P15 as follows:

• Touch or to select Code P15.

• Touch six seconds long. 6-5-4-3-2-1-
is counted down on the display.
• Initialization starts. INIT blinks on the display!
Note
• The time required for the initialization procedure depends
on the actuator transit time and can take a few minutes.
Initialization

• Initialization successfully completed,

positioner runs in closed-loop operation

• After a successful initialization, the positioner runs in

closed-loop operation indicated by the % closed-loop
operation icon and control position in % predetermined by
the reference variable on the display Configuration
is locked.
• A malfunction leads to the process being interrupted and
the positioner moving to the fail-safe position.
Zero Calibration

• In case of inconsistencies in the closing position of the

valve, e.g. with soft-seated plugs, it might be necessary to
recalibrate zero. Enable configuration

• Start the zero calibration by activating Code P16 as follows:

• Touch or until Code P16 appears.
• Touch six seconds long. 6-5-4-3-2-1- is
• counted down on the display.
• Zero calibration starts, the display blinks!
Zero Calibration

• The positioner moves the control valve to the CLOSED

position and recalibrates the internal electric zero point.
• When the zero calibration has been successfully completed,
the positioner returns to closed-loop operation (display with
status indication).

Canceling zero calibration

• The zero calibration can be canceled by touching
• ESC blinks on the display.
• Touch to confirm.
Manual Mode

• The valve position can be moved as follows using the

Manual mode function:
• Enable configuration
• Touch or until Code P17 appears.
• Touch six seconds long. 6-5-4-3-2-1- is counted down
on the display. P17 blinks.
• The manual set point (w man) is indicated on the display of
an initialized positioner.
Manual Mode

• The lever position in degrees in relation to the longitudinal

axis is indicated on the display of a positioner that has not
been initialized.

• Touch or to change the manual set point.

Initialized Positioner
• The manual mode starts using the last set point of the
automatic mode, ensuring a bump less changeover.
Manual Mode

• The bar elements on the display indicate the system

deviation between the manual and automatic set point while
manually moving the valve in Code P17.
• The manual set point is adjusted in steps of 0.1 %. You can
move the valve controlled within its range.
Positioner that has not yet been initialized
• Touch or longer to move the valve manually.
• The valve is only moved in one direction uncontrolled.
• The bar elements on the display indicate the change in
direction.
• Touch to deactivate the Manual mode function.
Manual Mode

• The Manual mode function can only be exited as described

or by interrupting the electrical supply (cold start).
• The positioner does not automatically exit this function and
return to the display with status indication.
Parameter Code list
Parameter Code list
Parameter Code list
Parameter Code list
Error Code list
Erorr Code list
Error Code list
Type 3730 Positioner Design & Operation
Type 3730 Positioner Design & Operation

DIP switches S1 to S10

• The positioner is mainly operated via the DIP switches,
which allow you to set the most important functions.
Type 3730 Positioner Design & Operation

4-20 ma Signal Dip Switches Span Adjustment Volume Restriction

Zero Adjustment Actuator Symbol for air connection
Type 3730 Positioner Design & Operation

ZERO and SPAN adjusters

• The ZERO and SPAN potentiometers are used to adjust the
starting point (zero) and the upper range value (span) of the
reference variable.

Volume restriction Q
• The volume restriction is used to adapt the air supply to
the actuator size. Depending on the air passage at the
actuator, two fixed settings are available.
Type 3730 Positioner Design & Operation

Adjusting zero
• Upon adjustment at the control valve, the travel must be
adapted to the reference variable.
• For example, with a reference variable of 4 to 20 mA, the
valve must also move through its full travel range from 0 to
100 % (Fig. 10, left).
• The starting point (zero) always refers to the closed
position of the control valve. Depending on the fail-safe
position of the valve "Actuator stem extends" (AIR TO
OPEN) or "Actuator stem retracts" (AIR TO CLOSE) and
the direction of action of the positioner
Type 3730 Positioner Design & Operation

• zero can either be the lower or upper range value (4, 12 or

20 mA) of the reference variable range
For "Actuator stem extends" (AIR TO OPEN):
Starting point (e.g. 4 mA)
• Adjust the input signal to 4 mA using an ammeter.
• Turn ZERO adjuster until the plug stem just starts to move
from its closed position.
• Interrupt input signal and slowly reapply it.
• Check whether the plug stem starts to move at 4.0 mA.
• Correct deviation at the ZERO adjuster.
Type 3730 Positioner Design & Operation

For "Actuator stem retracts“ (AIR T CLOSE):

Starting point (e.g. 20 mA)

• Adjust the input signal to 20 mA using an ammeter.

• Turn ZERO adjuster until the plug stem just starts to move
from its initial position.
• Increase the input signal and slowly decrease it back to 20
mA.
• Check whether the plug stem starts to move at 20.0 mA.
• Correct deviation at the ZERO adjuster
Any Question…
THANK YOU