® DRESSER INC.

Masoneilan
1250 Hall Court.• Deer Park , Texas • 281-884-1000 • Fax 281-884-1074

ENGINEERING PROCEDURE
APS-2006
Anti-Surge
SVI-IIAP Configuration & Set-up
Asymmetrical Single Acting Actuation

TABLE OF CONTENTS

1) SCOPE

2) SEQUENCE OF OPERATIONS

3) ACTUATOR ASSEMBLY

4) VALVE ASSEMBLY

5) POSITIONER CONFIGURATION

6) INITIAL NEEDLE VALVE ADJUSTMENT

7) POSITIONER CALIBRATION

8) ACTUATOR PERFORMANCE TESTING

9) FINAL NEEDLE VALVE ADJUSTMENT

10) DOCUMENTATION

10) PACKAGING

ATTACHMENTS#1:PNEUMATIC CONTROL SCHEMATIC WITH NEEDLE VALVE

#2:PNEUMATIC CONTROL SCHEMATIC WITH METERING VALVE
#3:WIRING CONTROL SCHEMATIC
#4: HART HANDHELD CONFIGURATOR FLOW-CHART

APS-2006 Rev. 0
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 ® DRESSER INC.
Masoneilan
1250 Hall Court.• Deer Park , Texas • 281-884-1000 • Fax 281-884-1074

1.0 SCOPE
This procedure details the operations involved and sequence of operations in the configuration, set-up and calibration
of a Masoneilan SVI-IIAP Smart Valve positioner for Anti-Surge control applications with spring return actuators in a
asymmetrical response configuration. Opening, closing times and over-shoot will be measured and evaluated in
compliance to Solar Turbines Specification requirements and “Source Control Drawing” compliance. This procedure
does not cover the performance testing of the over-ride system (Solenoid) in an open loop state.

2.0 SEQUENCE OF OPERATIONS

The actuator assemblies shall be processed in the following sequence. Descriptions of the specific operations are
listed later in this specification or in the reference specifications.
Actuator assembly shall be fully assembled prior to testing. Actuator will have the following adjustments and test
performed and documented using Valscope Diagnostics Console or Valvue 2.X for performance testing and
documentations.

Actuator Evaluation Pre-Test

Valve Assembly
Positioner Configuration
Needle Valve Initial Adjustments
Actuator Calibration
Actuator Performance Test
Needle Valve Final Adjustments
Documentation

3.0 ACTUATOR ASSEMBLY

Each Actuator assembly shall be fully assemble and tube up with all accessories mounted and properly supported,
accessories will include SVI-IIAP Smart Positioner, Filter Regulator, Solenoid Valve and Flow Control Valve (Metering
Valve). Control Schematic will be configured per “Source Control Drawing”, typical control schematic is depicted in
attachment #1 and #2. .

4.0 VALVE ASSEMBLY

Each valve shall be completely assembled and all components shall be visually inspected prior to assembly. After
final assembly, valve and actuator assembly should be couple together to include proper mechanical adjustments in
respect to valve stroke and seat press. Valve assembly should be pre hydro-statically tested and seat tested prior to
actuation performance testing.

APS-2006 Rev. 0
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 ® DRESSER INC.
Masoneilan
1250 Hall Court.• Deer Park , Texas • 281-884-1000 • Fax 281-884-1074

5.0 POSITIONER CONFIGURATION

For the purpose of configuring the SVI-IIAP positioner a number of configuration tools can be utilized, for example an
integral LCD & keypad, HART handheld configurator or Valvue 2.X. The two recommended communications are
Valvue2.X or Handheld. Within the configuration menu, configure the following typical parameters.
a) Characterization : Linear (Valve trim is designed as Equal Percentage on Globe Valves)
b) Air Action: Air to Close (Fail Open)
c) Tight Shut-Off: Disable (When enabled, it causes the actuator to fully saturate decreasing stroking speed).
d) Select “Configure I/O” sub-menu,
1) Configure Switch 1 (DO¹) as “5 Position Low Limit” (Close Switch) with a 2 (Two) percent trip set
point.
2) Configure Switch 2 (DO²) as “6. Position Upper Limit” (Open Switch) with a 98 (Ninety Eight)
percent trip set point.
3) Configure Re-Transmit position feedback (AO) as “Lower Range Value @ 4mA) to 100 (One
Hundred) which means that when the valve is close, feedback is 20mA.
4) Configure Re-Transmit position feedback (AO) as “Upper Range Value @ 20mA) to 0 (Zero) which
means that when the valve is open, feedback is 4mA.

Typical Configuration settings for Surge Control Applications

APS-2006 Rev. 0
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 ® DRESSER INC.
Masoneilan
1250 Hall Court.• Deer Park , Texas • 281-884-1000 • Fax 281-884-1074

6.0 INITIAL NEEDLE VALVE ADJUSTMENTS (METERING VALVE)

In accordance with the required pneumatic accessories, a needle valve in combination with check-valve shall be in
incorporated to provide variability in gaining or de-tuning the “Quick-Exhaust Valve”. A variable/adjustable “Flow
Control Valve” (Needle valve with integral check valve) can also be applied. Review control schematic in attachment
#1 and attachment #2.
Please note that the SVI-IIAP will “Auto-Tune” to highly gained pneumatics, however the advance tuning algorithm
will try to achieve symmetrical consistent behavior in large step changes where if additional speed response is
required, this can be achieve by closing (decreasing sensing feedback) needle valve. By tuning to 50% of potential
pneumatic gain, this provides adjustability if additional stroking speed is required.

a) Fully close needle valve (Feedback/bypass valve), then open (Counter-clock wise) 3 full turns or 50% of it’s
rated capacity (Cv).

7.0 POSITIONER CALIBRATION

Positioner calibration shall be perform using the two prefer HART communication tools, Handheld or Valvue2.X, the
following steps required the over-ride solenoid to be power so that the positioner can manipulate the control valve.
These steps and functionality are accessible from the Calibration menus.
a) Perform the function of “Find Stops”, this function will stroke the valve close and open allowing the SVI-IIAP
to identify the mechanical range (Stroke) of the actuator.
b) Perform the function of “Auto Tune”, this function will allow the SVI-IIAP to establish its PID tuning
coefficients.
The SVI-IIAP provides a user define “Aggressiveness Level” for auto-tuning, the allowable range varies
from -9 to +9 where 0 (Zero) is consider normal tuning. This proportionally influences stroking speed and over-shoot.
A negative value will increase (Slow) stroking speed however will minimized over-shoot. A positive value will
degrease (speed-up) stroking speed and manifest in some over-shoot.
The recommended values for “Aggressiveness “ in Anti-Surge configuration without volume boosters (only pilot
Quick-Exhaust valve) is between positive 1 and 3.

APS-2006 Rev. 0
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 ® DRESSER INC.
Masoneilan
1250 Hall Court.• Deer Park , Texas • 281-884-1000 • Fax 281-884-1074

8.0 ACTUATOR PERFORMANCE TEST

The following sequence of test shall be followed and documented. The equipment to measure and document
performance can vary from a stand alone portable diagnostics suit case like the Masoneilan Valscope or utilizing the
diagnostics support functionally of Valvue 2.X. For the purpose of factory acceptance testing, a Valscope unit should
be utilized. For the purpose of field adjustments or retrofits, using Valvue would be much easier.

8.1 TYPICAL PERFORMANCE REQUIREMENTS:

SOLENOID VALVE

With the valve command at 20 ma, removal of power from the solenoid, shall cause the valve to reach 63.2% of full open in
less than 100 + 100(port size in inches)0.5 milliseconds.

100 + 100 PORT SIZE IN INCHES

Example: A 4” valve, 4.375” port, must reach 63.2% open in less than 309 milliseconds

POSITIONER

With a step change from 20 to 12 ma, the valve shall reach 50% open in less than 300 + 100(port size in inches)0.5
milliseconds (maximum half opening time).

300 + 100 PORT SIZE IN INCHES

Example: A 4” valve, 4.375” port, must reach 50% open in less than 509 milliseconds

OVERSHOOT

The valve shall not overshoot its ultimate destination by more than 60%. Responding to the 20 – 12 ma step change above,
the valve shall have a maximum excursion not to exceed 80% open.

After the overshoot the valve shall return to it’s ultimate position (50% open) in less than 10 times its maximum half opening
time.

OVERSHOOT AREA

The following reduces the area bounded by the preceding two limits by half. This is done by limiting overshoot to an area
beyond the ultimate travel destination (overshoot triangle).

The area beyond the ultimate destination (overshoot triangle) shall be less than 1.5 where:

Area = B*H/2.

B = Recovery time (X2) over maximum half opening time.

H = Percent overshoot (Y).

Example: A 4” valve, 4.375” port, at maximum overshoot, must return to its ultimate destination in 5.09
seconds.

Example: A 4” valve, 4.375” port, at maximum recovery time, must have no more than 15% overshoot.

If there is a second "ring" returning from the overshoot, it shall not exceed 2.5% of the total valve travel.

Valve minimum resolvable position (stick & slip) shall not exceed 2% of the total travel.

APS-2006 Rev. 0
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 ® DRESSER INC.
Masoneilan
1250 Hall Court.• Deer Park , Texas • 281-884-1000 • Fax 281-884-1074

8.2 INITIAL PERFORMANCE TEST (STROKING SPEED)

a) Using Valvue 2.X, perform a “Std. Actuator Signature”, this signature will provide analyzed text results
including “Response Open”, “Response Close”, “Friction”, “Lower Spring Range”, “Upper Spring Range” and “Supply
Pressure”. Please note that “Response Open” represents full stroke from Close to open.
Please note that “Valvue2.X Light” will support configuration, calibration and commissioning however will not provide
functionality or support for the purpose of reporting and performing diagnostics. This functionality is only available
with Valvue2.X full package.

b) Using Valvue2.X perform a “Step Test” with the following user testing criteria:
1) Start Position (%): 0
2) Stop Position (%): 50
3) Time (s): 5
4) Sample Rate (Samples/s) : 20
5) Step Size (%): 50
6) One Way (Direction to Open)

This test will provide a graph and analyzed test results which identify T86 or stroking speed to reach 50% of
valve stroke including “Overshoot”.

Step Response Test parameters for 0 to 50% of valve stroke

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 ® DRESSER INC.
Masoneilan
1250 Hall Court.• Deer Park , Texas • 281-884-1000 • Fax 281-884-1074

The graph can be analyzed to determine “Dead Time” or sometimes define as “Microprocessor execution”
including “pneumatic lag” and “mechanical response”.
On the sample below, the “Dead Time” is calculated @ 100 milliseconds, “Step Response Test Results” can
be access by selecting “Show Diagnostics Info” icon.

Step Response Test Graph for 0 to 50% of valve stroke

8.3 EVALUATION OF PERFORMANCE TEST

If specification requirements are not met, needle valve adjustment in the direction of clock-wise will increase speed
response however it will influence overshoot. You will have to find the ideal dynamic range where stroking speed
requirements are met with minimum overshoot. Once performance criteria are met, repeat and document step 8.2 and step
8.4. See step 9.0 for basic instructions of “Final Needle Valve Adjustment”.

APS-2006 Rev. 0
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 ® DRESSER INC.
Masoneilan
1250 Hall Court.• Deer Park , Texas • 281-884-1000 • Fax 281-884-1074

8.4 FINAL PERFORMACE TEST

The final performance test is to perform and document a “Step Response Test” where the control valve is driven from
the close position to the full open position and back to the close position, this test will identify stroking speed response
in both directions.

a) Using Valvue2.X perform a “Step Test” with the following user testing criteria:
7) Start Position (%): 0
8) Stop Position (%): 100
9) Time (s): 5
10) Sample Rate (Samples/s) : 20
11) Step Size (%): 50
12) Two Way (Both directions)

Step Response Test parameters for 0 to 100% and 100% to 0 of valve stroke

APS-2006 Rev. 0
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 ® DRESSER INC.
Masoneilan
1250 Hall Court.• Deer Park , Texas • 281-884-1000 • Fax 281-884-1074

The graph can be analyzed to determine “Dead Time” or sometimes define as “Microprocessor execution” including
“pneumatic lag” and “mechanical response”.
On the sample below, the “Dead Time” is calculated @ 100 milliseconds, full stroking speed is reach in 2
seconds. “Step Response Test Results” can be access by selecting “Show Diagnostics Info” icon.

Response “Dead Time” 100 milliseconds

Stroking Speed @ 50% open 700 milliseconds

Step Response Test Results

APS-2006 Rev. 0
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 ® DRESSER INC.
Masoneilan
1250 Hall Court.• Deer Park , Texas • 281-884-1000 • Fax 281-884-1074

8.5 ACCESSORIES PERFORMANCE TESTING

All accessories like programmable discrete output switches shall be set and test while the valve assembly is on the
test stand. Switches shall be set to indicate Open and Close respectively.

9.0 FINAL NEEDLE VALVE ADJUSTMENTS

If additional speed is required, this can be perform by gaining the pneumatic system. Pneumatic gain is adjusted by
decreasing (Closing Needle Valve) feedback, this will increase sensitivity of the pilot Quick-Exhaust valve.
This becomes a balancing act where low gain will manifest in slow stroking response, aggressive gain will manifest in
excessive overshoot and potentially limit cycling. Do not over-gain the system, if stroking speed requirements are not
met with current “Auto-Tune” PID coefficients, re-Auto Tune with the needle valve open to 25% of effective capacity
and select a higher value for the “Aggressiveness Level” of “Auto-Tune.
Please note that if you adjust the needle valve or re-tune, performance tests shall be repeated in the sequence
described in section 8 of this procedure.

10. DOCUMENTATION
For the purpose of documentation, as a minimum using Valvue 2.X, a “Dump File” should be save after all
configuration and final tuning is achieve along with a performance report which is also created by Valvue 2.x.

11. PACKAGING
After completion of testing the complete assembly shall be sealed to protect the end connections and maintain
cleanliness during shipment. End connections should be protected to prevent shipment damage.
.

ENGINEERING _______________________________________

QUALITY ASSURANCE _______________________________________

Copyright 2006 as an unpublished trade secret. This document and all information herein is the property of Dresser Inc. It is confidential and must
not be made public or copied and is subject to return upon demand.

APS-2006 Rev. 0
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 ® DRESSER INC.
Masoneilan
1250 Hall Court.• Deer Park , Texas • 281-884-1000 • Fax 281-884-1074

Pneumatic Control schematic attachment #1

APS-2006 Rev. 0
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 ® DRESSER INC.
Masoneilan
1250 Hall Court.• Deer Park , Texas • 281-884-1000 • Fax 281-884-1074

Pneumatic Control schematic Attachment #2

APS-2006 Rev. 0
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 ® DRESSER INC.
Masoneilan
1250 Hall Court.• Deer Park , Texas • 281-884-1000 • Fax 281-884-1074

Electrical Control Schematic Attachment #3

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 ® DRESSER INC.
Masoneilan
1250 Hall Court.• Deer Park , Texas • 281-884-1000 • Fax 281-884-1074

A C
B
Calibration Manual Positioning
Configuration 1 Mode: Setup 1 Valve Position X.X %
1 Reset Basic Config and Cal Defaults 2 Change Mode 2 Full Open
**Device Setup **
2 General 3 Valve Travel 3 Full Close
1 Mode Normal/Manual/Setup
3 Actuator Type 4 Manual Position 4 Set Position
2 Change Mode Set Mode Target
1 Normal 4 Positioning 5 Valve Tuning Data
3 Setup Wizard Sensors
2 Manual 5 Limits/Shutoff 6 Sensors
4 Manual Setup
6 Alarms Setup 7 Reset Cal Factory Defaults 1 Input Current Sensor
5 Configuration B 3 Setup
2 Pressure Sensor
7 Switches
6 Calibration C
7 Commissioning Services 8 HART Enter Value (mA)
Valve Travel Low Range
D 9 Device Info 1 Mode: Setup
2 Change Mode High Range
Air Action Configuration
1 Skip This Task 3 Find Stops Open Stop Adjustment
2 Select Air Action General 4 Open Stop Adjustment
Enter Value XX.XX %
Manual Setup Are you sure? 1 Tag : 5 Manual Stops
1 Mode Setup Select Air Action 2 Descriptor 6 Autotune
ABORT Set Manual Stops
2 Reset Basic Configuration Air To Close 3 Message 7 Manual Tuning
OK
3 Configure Wizard Air To Open 4 Date 1 Low
5 Final Asmbly Nbr P 2 High
4 Find Stops
5 Auto Tune 6 LCD Language I 3 Exit
7 Local Buttons
Find Valve Stops D
8 Pressure Units Aggressiveness Level
1 Skip This Task
9 switch positions DEL
Allow Override Limits 2 Run Find Stops Padj
ABORT
Enabled Beta ENTER
Disabled Actuator Type
1 Air Action : ATO/ATC Stroke Time -9 to +9
Auto Tune
1 Skip This Task 2 Type : Single/Double 0 Normal Tuning
Compens. pos
Select Tight Shutoff 2 Run Auto Tune
Enabled Dead Zone
-9 to +9 Positioning
Disabled 1 Characterization: Linear/EQ50/EQ30/QO/Camflex Boost
0 Normal Tuning
2 Low Signal: 4.00 mA
Value 3 High Signal: 20.00 mA
XX.X 4 Bumpless Transfer: Disabled/Enabled Switches D
Reset to Factory Default 5 Allow Override Limits : Disabled/Enabled 1 DO Switch 1 Action : Commissioning Services
1 Skip This Task 6 Position Sensor: Built-in Sensor / Remote 2 DO Switch 1 Normally Open/Close
Pressure Units 2 Set All Values to Default 1 Mode : Setup
7 Custom and/or Standard Characterization : 3 DO Switch 2 Action:
psi 2 Input Signal: XX.XX mA
4 DO Switch 2 Normally Open/Close 3 Valve Position X.X %
bar Select Cam
kPa 4 Basic Info
Warning Linear HART 5 Manual Position
ABORT Equal % (30) 1 Poll Addr : 0 (Typical) 6 Position Retransmit
OK Equal % (50) 7 Run Diagnostics
Display Language 2 Nbr Of Preambles: 5 (Typical)
Quick Open 3 Phys Sign Code : Bell 202 Current
English Custom 8 Switches
French Please wait 4 Device Flags : 0X00
Camflex-Equal %
ABORT 5 Burst Mode; Off/On
6 Burst Command : CMD 3 **NORMAL MODE **
OK 1 Mode : Normal
Button Lock Level Limits/Shutoff
1 Position Limit Low : Disabled/Enabled Device Info 2 Input Signal : X.XX (mA )
All Enabled Aggressiveness Level 2 Low Limit : 0.0 % (Typical) 3 Valve Position: XX.X (% )
No Config/Cal Manufacturer
DEL 3 Position Limit High: Disabled/Enabled 4 Manual Setpoint: XX.X (%)
No Manual ABORT 4 Limit High : 100.00 % (Typical) Model 5 Read Pressures
Locked ENTER 5 Tight Shutoff: Disabled/Enabled 6 Device Setup A
Device ID
6 Tight Shutoff Value: XX.X % (Signal) 7 Status/Diagnostics
375 Handheld Select Air Action Universal Cmd Rev
Communicator Air To Close -9 to +9
Air To Open 0 Normal Tuning Alarms Setup Hardware Rev
Guide for SVI-IIAP 1 Near Close Value : Value XX.X %
** Read Pressures**
Trans Cmd Rev 1 Pressure Unit psi
Firmware 3.11 2 Pos Error : Disabled/Enabled 2 Actuator Pressure : X.XX
Valve Near Closed Value 3 Pos Error Band : XX.X % Software Rev
XX.X (%) A 4 Pos Error Time: XXX s
Firmware Version

HART Hendheld Configurator Flow-Chart

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