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Calibration Procedure of A Control Valve
Calibration Procedure of A Control Valve
Control valves are devices that perform the function of regulating the flow of a
fluid. The control valves receive the command signals from the PID controllers
in a PLC or a DCS system. The valve positioners adjust the instrument air-
flow to the valve actuator as per the received signal from the PLC or DCS
systems.
This allows the control of the fluid flow through the valve and the consequent
control of the variables of the process such as pressure, temperature, and
level.
Control valves are classified into several types. According to the stem
movement, they can be rotary or linear valves. Based on the action, they can
be air to open or air to close. Based on its actuation, it can be a diaphragm or
cylinder pressurized, and so on.
Calibration Procedure
All above-said practices differ slightly from process plant to plant as per their
particular needs.
Before starting the job, take proper work permits and inform the process
engineers and take the isolation of the valve if required. Place the PID
controller in manual mode in the PLC or DCS systems.
Step-by-step procedure:
2. Once the operating range and the type of valve action have been
determined, a pressure simulation will be applied to calibrate it. It is nothing
but a stroke test to determine the full open and full closure of a valve.
3. Now, let us calibrate a valve with 3-15 PSI, if it is a reverse action (air to
open) then the valve will be closed, it begins to simulate pressure little by little
and it should start opening at approx. 3 PSI. The valve travel indicator must
be at 0%.
4. When we apply with 3 PSI then the valve will be at 0%. Next, we proceed to
apply 15 PSI then the valve must open 100%, and the stroke indication shows
full scale.
6. The verification of 0% and 100% are repeated a number of times that are
necessary until the valve is correctly calibrated.
Note: the above steps have been done with a reverse-acting valve (closes no
air).
3. With a signal of 3 PSI the valve must be at 0%. If it is not the case with the
Zero screw you adjust the position of the valve so that it is closed.
4. When the positioner sends 15 PSI output to the valve actuator the valve
adjusts its position to 100%. If not the case, adjust the span screw so that it
gives said opening value.
5. As many times as necessary, these steps will be repeated until the valve
shows correct readings i.e. open and close parameters.
The below calibration procedure for a control valve with a smart positioner.
We can also call this an electro-pneumatic positioner with a control valve.
1. In the calibration procedure of a pneumatic Positioner this is done
mechanically and with control air.
4. To check the 100% opening, 20 mA is simulated and this will show the
valve’s 100% position. If there is some problem then connect the HART
communicator to the valve positioner and then start the calibration.
5. In some control valves, you will be provided with a display and control
buttons. You can use these to check the valve position status and also you
can start the calibration. (no need for a HART communicator)
Keywords
Air to open: The air-to-open control valve is held close by the spring force,
and the pneumatic signal makes it open. Also called Reverse action.
AFR: AFR means Air Filter Regulator. The AFR is used to adjust the required
instrument air to the control valve.
Control Valves
Comments
1
Pertinent… Merci
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