Control valve
position sensors
Department Editor: Scott Jenkins
T
he precise monitoring and control of
valve position is essential for efficient au-
tomation of both discrete and continuous
processes. Measurement of valve position
provides the data required for the use of
advanced control strategies and predictive
maintenance algorithms.
More effective monitoring of valve posi-
tion has been an area in which consider-
able progress has been made in improving
the performance and reliability of control
valves. Modern electrical valve-position
indicators offer either mechanical or non-
contact switching. The position indicators
are typically mounted either directly on a
valve actuator or work indirectly using a
non-contact remote feedback device.
Mechanical switches
Most mechanical-switch valve positioners
(Figure, top left) utilize some type of rotary
potentiometer for converting linear to rotary
feedback. These widely used devices are
similar to variable resistors.
Rotary potentiometers have an arched coil
of wire, over which an arm, called a wiper,
slides. The wiper is attached to the valve
cam shaft, and as it moves across the coil of
wire, a differing voltage output is produced.
The voltage output is proportional to the
angle at which the wiper is oriented.
Mechanical switches include contact link-
ages that are subject to wear over time. The
wear can eventually degrade performance.
Non-contact proximity positioners
Non-contact technology approaches to
valve positioning can provide accurate
valve-position data without the need for the
linkages or levers required by traditional
systems. Avoiding mechanical contact in the
valve positioning system addresses some
of the performance and cost challenges
associated with control valves, including
mechanical wear, environmental hazards,
human error and inaccurate readings.
Many non-contact proximity positioners
(Figure, top right) incorporate a control-
loop feedback mechanism based on an
analog PID (proportional integral deriva-
tive) algorithm that has been updated for a
digital device. The algorithm incorporates
the Ziegler-Nichols (Z-N) tuning procedure,
a well-known method for tuning automatic
controllers. It is a two-step tuning approach
that adjusts how agressively the valve con-
troller reacts to errors between the process
variable and the desired setpoint.
Hall-effect sensors
A number of non-contact proximity position-
ers are based on the solid-state Hall effect,
and are used to help improve monitoring
and control of production processes. The
Hall effect refers to a potential differ-
ence, known as the Hall voltage, between
opposite sides of an electrical conductor
through which an electric current is flowing.
The Hall effect is created Limit Switch Options
when a magnetic field is
applied perpendicular to
the current direction.
A sensor using the
Hall effect is a trans-
ducer that returns a volt-
COM
age output according to
changes in the magnetic
NO
NC
field. For valve position
sensing, an integrated
Hall-effect sensor and
magnet assembly detect
the presence, absence
and orientation of a
magnetic trigger. The Mechanical Solid state Reed proximity
switch sensor switch
sensor is powered by
a constant current, and
develops a varying
electrical potential
that is proportional to
the flux density of a
magnetic field applied
perpendicular to the
axis of the sensor.
Hall-effect proxim-
ity sensors used for
valve positioning offer
increased reliability in
extreme environments.
These sensors eliminate
all mechanical contact
between the valve actua-
tor and the transmitter.
Because there are no
moving parts within the
Hall-effect sensor and magnet, the life Improved reliability — Safety integrity level
expectancy is improved compared to a (SIL) ratings are higher with non-contact
traditional electromechanical switch. sensors and low-power solenoids. SILs are
a measure of safety system performance.
Reed switches Higher SIL numbers mean better safety
Some non-contact valve positioners are performance and higher confidence in the
based on reed switches. A reed switch is field device.
an electrical switch that is operated by an Lower costs — Non-contact valve position-
applied magnetic field. Reed switches have ers have a lower overall total cost of own-
a pair of electrical contacts on ferrous metal ership than conventional devices, thanks
reeds in a hermetically sealed glass enve- to the precise positioning capabilities that
lope. An applied magnetic field moves the can be customized by valve application.
reeds, causing the contacts to either touch Also, the cost of ownership is lowered by
or move apart. The contacts can either be ease of calibration and service, and rich
open normally, closing when a magnetic diagnostics for predictive maintenance
field is present, or closed normally, opening signatures.
in the presence of a magnetic field. Bifur- Increased versatility — Non-contact valve
cated reed switches can be used in applica- positioners are designed to be compatible
tions where ultralow power or capacitive with most standard industrial communica-
discharge consideration are in effect. tions protocols, including HART, Foundation
Fieldbus, AS-I, Modbus, DeviceNet and
Benefits Profibus. These devices can help engineers
Significant benefits for non-contact valve take advantage of the cost savings and in-
positioners, include the following: creased diagnostic capabilities of networks,
Greater flexibility — Non-contact position- along with the advantages offered by
ers utilizing Hall-effect sensors provide improved position sensors.
feedback on valve position without link-
ages, levers or rotary or linear seals. This Notes
allows a remote sensor-head assembly to This edition of “Facts at Your Fingertips” was
be mounted a considerable distance from adapted from Jack DiFranco’s article, entitled Ad-
the electronics enclosure, giving engineers vances in Valve Position Monitoring, that appeared
in the December 2007 issue of Chemical Engineer-
increased flexibility and improved safety. ing, pp. 46–50.