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Lecture 6 - Industrial Instrumentation and Actuators - 3
Lecture 6 - Industrial Instrumentation and Actuators - 3
CONTROL SYSTEMS
Lecture 6. Industrial
instrumentation and actuators
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Presentation Outline
▪ Hydraulic actuator
▪ Pneumatic actuator
• Control valves
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Industrial Actuators
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Introduction
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Linear Actuator
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Leadscrew linear actuators
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Example 1
An electric linear actuator is used to lift 600
lb castings for a vertical distance of 8 in.
Using the data from beside figures, how long
will the lifting operation take?
Performance characteristics of a
typical electric linear actuator
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Solenoids
A solenoid is a simple electromagnetic device that
converts electrical energy directly into linear
mechanical motion, but it has a very short stroke
(length of movement), which limits its
applications.
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Solenoids
Both AC and DC solenoids are used, the major difference being that AC solenoids use a
plunger and frame made from laminations instead of solid iron. Laminations are thin sheets of
lacquered iron that are riveted together to form the frame and plunger. Laminations prevent
power-consuming eddy currents (induced by the AC) from circulating in the metal parts of the
solenoid.
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Solenoids
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Electric Linear Motors
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Hydraulic systems
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Example 2
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Example 3
A 2-in. diameter hydraulic cylinder is being supplied with a
pressure of 1000 kPa.
Find the force exerted on the piston in pounds.
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Static hydraulic systems can be used to “amplify” a force. The system contains two cylinders of
different diameters that are connected by a tube. When a force is applied to the small piston, a
pressure develops. This same pressure is transmitted through the tube and is applied to the large
piston. Because the large piston has more surface area, it receives a larger net force. Of course, it is
also true that the large piston will move a shorter distance than the small piston because the work
done by the two pistons must be the same.
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Hydraulic Pumps
In an active hydraulic system, a pump is used to create the hydrostatic pressure.
There are 3 types of hydraulic pumps
• Gear pump
• Vane pump
• Axial piston pump
Hydraulic Pumps
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Hydraulic Pumps
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Hydraulic Pumps
Vane pump consists of an offset rotor in a housing with retractable vanes. The
spring-loaded vanes push out and seal against the housing wall. Because there is
more fluid between the vanes in the top half of the housing than in the bottom, there
is a net transfer of fluid from the inlet to the outlet. In some designs, the position of
the rotor axis is adjustable. The more offset the rotor axis, the more fluid is pumped.
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Hydraulic Pumps
An axial piston pump uses small pistons reciprocating back-and-forth to pump the
fluid. the pump consists of a rotating cylinder and a metal ring called a swash plate
(which does not rotate). The cylinder contains a number of small pistons that do the
actual pumping. One end of each piston rides against the swash plate. Because the
swash plate is at an angle to the cylinder, each piston is forced to move in-and-out
with each rotation of the cylinder. By changing the angle of the swash plate, the
quantity of fluid pumped per revolution is changed
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Hydraulic actuators
The most common type of hydraulic actuator is the hydraulic cylinder. It consists of
a piston and a cylinder body. The piston has a rod that extends out one end of the
cylinder. Fluid can enter and leave the cylinder on either side of the piston through
ports. Under normal operating conditions, both ends of the cylinder are filled with
fluid. If additional fluid enters port A, the piston will move toward the right, but the
fluid must be able to escape through port B.
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Hydraulic actuators
Some hydraulic actuators can create rotary motion and are very similar to the pump
designs discussed previously. For example, the gear motor rotary actuator shown in
under figure is almost identical to the gear pump. For the motor, fluid is pumped in
the left side of the case, putting that area under pressure (indicated by p). Within the
pressurized area, all surfaces receive a force, but only those three surfaces
indicated with arrows will affect rotation (the other surfaces are balanced out or
unmovable). The pressure on the teeth next to the case (top and bottom arrows) will
cause the gears to rotate as shown. The pressure on the meshing teeth in the
center would cause the gears to turn in the opposite direction, but this torque is
overpowered because two teeth (top and bottom) are pushing the other way.
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Pressure control valves
A pressure-control valve is a spring-loaded valve that is capable of maintaining a
constant pressure in a system, regardless of the flow rate. If the pump were
connected directly to the cylinder, it would have to start and stop each time the
piston moved to a new position. When a pressure-control valve is put into the
system, the pump can remain on the whole time—when the fluid pressure exceeds
the preset limit, the valve opens, and the surplus fluid is simply returned to the tank.
In other words, when the piston is not moving, the fluid is simply circulating from the
tank, through the pump, through the valve, and back to the tank. If the pressure-
control valve opens at 1000 psi, then the pressure in the lines will never get much
above 1000 psi.
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Accumulators
An accumulator, which is connected into the system, is a special kind of spring-loaded
storage tank for hydraulic fluid (Figure 10.20). The accumulator serves two functions. First, it
acts as a low-pass filter to remove pressure pulsations from the pump; second, it stores extra
fluid for those high-demand times when the actuator requires fluid at a faster rate than the
pump can supply.
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Directional Control Valves
A basic hydraulic system includes the tank, filter, pump, accumulator, pressure-
control valve, directional control valve, and cylinder. The constant-displacement
pump would be running all the time the system is on. During those times when the
cylinder is not moving, the fluid from the pump, after filling the accumulator, returns
to the tank through the pressure-control valve. Of special importance is the filter that
removes small contaminants, which can get into the fluid. These contaminants can
cause abrasive wear on the system components and reduce their lifetime
considerably.
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Pneumatic systems
Pneumatic systems use air pressure to create mechanical motion. The basic system
includes an intake filter that traps dirt before it enters the system, an air compressor
that provides a source of compressed air a dryer that removes the moisture in the
air, a pressure tank that is a reservoir of compressed air, a pressure regulator that
maintains air pressure, a valve that controls the air flow, and a pneumatic cylinder
that creates the mechanical motion
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Pneumatic systems
Pneumatic systems are very similar to hydraulic systems, but there are several
important differences.
The major functional difference is that air is compressible, whereas hydraulic fluid is
not.
Another difference between hydraulic and pneumatic systems is that pneumatic
systems do not have to return the low-pressure air to the compressor
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Compressors, Dryers, and Tank
The air compressor is a machine that
pumps air from the atmosphere into a
tank. There are a number of types of
compressors, but one of the most
common is the reciprocating piston
compressor.
The compressor crankshaft is driven
by an external power source,
typically an electric motor. As the
crankshaft rotates, the piston is
forced up-and-down in the cylinder.
The air is drawn into the cylinder
through a valve during the intake
stroke then during the exhaust
stroke, the air is pushed out through
another valve into the pressure tank.
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Pressure Regulators
The tank pressure can range anywhere between the high and low limits of the pressure
switch. Some systems cannot tolerate this variation and hence require a pressure regulator to
be installed between the tank and the system components. The pressure regulator can
supply air at a constant pressure regardless of the source pressure as long as the source
pressure stays above the desired regulated pressure. A spring-loaded diaphragm is pushed
on by regulated air pressure. If the regulated air pressure starts to fall, the reduced pressure
on the diaphragm causes it to move downward, thus opening a valve and allowing more high-
pressure air in.
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Pneumatic Control Valves
Pneumatic control valves regulate the air
flow, which in most cases means on or
off. Many configurations are possible, but
of particular interest is the bidirectional
control valve that causes a piston to
move in either direction. A pneumatic
bidirectional control valve is functionally
similar to the hydraulic control valve
shown in figure in slide 33, but there are
some differences. For instance,
pneumatic control valves use O rings
(rubber seals) to minimize internal leaks.
Pneumatic valves are usually designed to
be full on or completely off and are driven
by either an electric solenoid or a
pneumatic control signal. Finally, these
valves require only one tube coming.
Cutaway view of a pneumatic control valve
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Pneumatic Actuators
Pneumatic actuators convert air pressure into mechanical motion. There are two basic types:
linear actuators (cylinder/piston or diaphragm types) and rotary actuators. Piston and rotary
actuators are functionally similar to their hydraulic counterparts. Pneumatic cylinders are
available in a variety of shapes and sizes. There are two basic internal configurations. The
double-acting cylinder connects to the valve with two tubes and can be driven in either
direction. The single-acting cylinder can only be driven in one direction with air pressure and
is returned by a spring.
Pneumatic cylinders
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Example 5
A spring-loaded single-acting cylinder has a diameter of 2 in. and a stroke of 2 in.
The return spring has a spring constant of 3 lb/in. The available air pressure is 30
psi. What force can this cylinder supply to a load at the end of its stroke?
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Pneumatic Actuators
Rotary actuators convert air pressure into rotary mechanical motion. One common
design is the vane motor. The motor consists of a rotor that is offset in a housing.
Protruding from the rotor are spring-loaded vanes that seal against the housing and
slide in-and-out of the rotor as it turns. Motion is achieved because the vanes on the
top have more exposed surface area than those on the bottom and hence receive
more force, causing the rotor to turn clockwise.
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Control valves
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Introduction
❑ A valve is a device that regulates, controls, or controls the
flow of a liquid (gas, liquid, liquefied solid, or slurry) by
opening, closing, or partially obstructing various
passages. This opening and closing can be done
manually or by pneumatic, electrical or hydraulic
actuators in response to an external control signal and is
called a Control Valve.
❑ Control Valve
▪ Acts as an actuator in the control loop that is
responsible for receiving control signals and directly
controlling the flow.
▪ Maintain parameters such as pressure, flow,
temperature or level at desired values, despite
changes in dynamics and loads.
▪ Designed with characteristics suitable for the type of
fluid it controls, similar to meeting the protocols of the
control device.
❑ The development of Control Valves in response to the
processes they or the systems they control manifests
itself in such elements as the design of the valve body,
actuator, controller and interface fittings.
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Parameters to evaluated the
Performance of Control Valves
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Deadband
• Dead band is the range through which an input can be
varied without initiating an observable response.
• For example, in a diaphragm, actuated control valve dead
band is the amount with which the diaphragm pressure can
be changed without causing the valve stem to move.
• Studies suggest that dead band is one of the major
contributors to excess variability. The control valve
assemblies can be a primary source of dead band in an
instrumentation loop. It is usually expressed as a
percentage of diaphragm pressure spans. Backlash and
striction behavior is caused by mechanical tolerances and
friction in the control valve-positioner-actuator-linkage
system. Friction and backlash, and dead zones in relays
are some forms and reasons for the dead band. Most
process control applications using advanced systems send
signals which are very small (sometimes less than 1
percent).
• A well-designed valve is expected to respond to these
small changes to keep a tight control on the process. If the
dead band is more, the valve may not respond to these
signals which in turn creates disturbance to the process
and hence to the process variability.
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Valve Type and Sizing
❖ While selecting a valve, consider the
valve style, valve size, and inherent
Choosing the correct valve size is as equally characteristics that provide the broadest
important as choosing appropriate control valve possible control range for an application.
materials and pressure temperature ratings. The economic results of an operating
❖ Oversized valves limit the efforts of plant are directly impacted by the
reducing process variability. The pipes performance factors. These parameters
may be designed larger than required (like response time, dead time or gain)
considering some future plans and are measured in open-loop and closed-
safety factors and some larger rotary loop conditions. Control valve assemblies
manual ball valves etc. The oversized play a vital role in loop/unit/ plant
control valves operate at lower levels of performance. The parameters (material
positions due to less flow. If the valve of construction, flow capacity, leakage
has dead band, the situation becomes and open-loop lab performance data) are
even worse. The large flow of liquid in
sudden jerks leads to process variability. not treated as not enough to specify and
select valve, unless the dynamic
characteristics are specified. This is the
fact that a single subsystem cannot be
specified in isolation to achieve loop
performance.
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Linear trim
Equal percentage trim
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Valve Type and Characterization
❑ Most control valves used in the process industry have one of the three flow characteristics:
linear, quick-opening, or equal percentage.
▪ Linear: the straight line on a rectangular plot of flow versus percentage of rated valve
stem travel. A linear valve gives approximately equal increments of flow per increment
of valve stem travel at a constant pressure drop.
▪ Equal Percentage: the equal increments of rated travel will ideally give equal
percentage changes of the existing flow.
▪ Quick-opening: maximum flow achieved with minimum travel. A quick-opening valve
has an approximately straight-line characteristic near its seat (from 0 to about 60% flow
at 30% travel). Beyond this point, flow increases too rapidly with valve opening for the
quick opening characteristic to be useful in a flow-proportioning application.
❑ Valve characterizations can be changed by reshaping the valve trim. For example,
modifying the plug proles of a single-ported, stem-guided globe valve will give you the
typical linear, quick-opening, and equal-percentage characteristics.
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• The few weld-end buttery and ball valves that where the pressure drop is rather
are available are rather expensive. minimal. Rotaries, on the other hand, are
not ideal for high-pressure drop
applications (letdown or pressure
regulation).
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Control Valve Performance Considerations
Shutoff Capability
❑ A valve’s shutoff capability, which ordinarily is rated in terms of classes specified in ANSI/
FCI 70-2 [4] or IEC 534–4, must also be considered during valve selection. In real time
service, shutoff leakage depends on various factors that include temperature, the condition
of the sealing surfaces, pressure drop, and stem valves (very importantly for sliding). Stem
valves force load on the seat. Shutoff ratings are generally stated based on standard test
conditions. The actual service conditions will be different from standard conditions.
However, it is difficult to predict the leakage at service conditions and hence the standard
conditions are used for comparison among different types of valves.
❑ Tight shutoff is particularly important in high-pressure valves because leakage can cause
seat damage, leading to ultimate destruction of the trim. Special precautions in seat
materials, seat preparation, and seat load are necessary to ensure success. Valve users
tend to over specify6.10 Instrumentation and Control Systems shutoff requirements,
incurring unnecessary cost. Actually, very few throttling valves really need to perform
double duty as tight block valves. Since tight shutoff valves generally cost more initially and
to maintain serious consideration is warranted.
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Valve Sizing
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Valve Sizing
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Valve Sizing
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Valve Sizing
Choked flow
❖Sizing equations suggest that as the pressure
drop is increased, flow increases proportionally—
forever. As the pressure drop is increased,
choked flow caused by the formation of vapor
bubbles in the flow stream imposes a limit on
liquid flow. These choked-flow conditions must be
considered in valve sizing.
❖If the pressure drop across the valve is
increased, the flow rate increases. The situation
reaches a point where there is no additional flow
rate increase for any additional increase in
pressure difference. This condition is referred as
chocked flow. This phenomenon occurs on both
liquids and gases.
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Valve Sizing
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▪ Seat ring: A seat ring in the valve provides the surface for plug and
is part of orifice created for flow control.
▪ Stem connector: The device that connects the actuator stem to the
valve stem.
▪ Yoke: Yoke is the structure that rigidly connects the actuator power
unit to the valve.
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Control Valves, Terminology and Types
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Sliding-stem Valves
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Control Valves, Terminology and Types
Sliding-stem Valves
•Three-way valves have three end connections to allow for
converging or diverging operations. It is available in two
variations—diaphragm valve and the pinch valve. The
diaphragm valve uses a linear actuator to squeeze the
diaphragm onto a hard seat formed in the valve body. One
major disadvantage of these valves is that the elastomer
deteriorates above 100°C and its strength limits operating
pressure to 500 kPa or less. More choices of materials, end
connections, and control characteristics are available for
sliding-stem valves than for any other product family.
Sliding-stem valves are available in cage-guided, port-
guided, and stem-guided designs with flanged, screwed, or
welding ends.
•The important point to note here is that there is a cage in
which the valve plug always sits and its motion is guided
throughout. The arrangement does not allow the leakage of
the inlet fluid in high pressure to outlet in low pressure.
Outlet pressure acts on both sides of the plug and removes
the static unbalancing force acting on it there by reducing
the thrust required on the valve.
Three-way valves
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Control Valves, Terminology and Types
Ball Valves
• The ball valve is a typical valve where the ball or plug can
be rotated within the body through a quarter of a turn. The
plug has a passage through it. There are three variations of
the ball
• valve. In the first, the plug is a ball with a line sized circular
flow passage, offering minimal flow restriction when fully
open. The second is a ball with a V-shaped passage,
enabling smooth control at low and high flows. The third is
the cock which uses a conical shaped plug.
• While cocks are traditionally popular in the gas industry,
they are seldom used as automatic control valves because
the plug tends to jam in the body. Valves employing a
rotatable plug achieve tight shutoff.
• There are two subcategories of ball valves. The through-
bore or full-ball type valve shown in Figure 6.11 is often
Ball valve used for high-pressure drop, throttling and on/off
applications in sizes to NPS 24 or DN 600. Full-port designs
exhibit high flow capacity and low susceptibility to wear by
erosive streams. However, sluggish flow throttling response
in the first 20% of ball travel makes full-bore ball valves
unsuitable for throttling applications. Newer designs in full-
ball, reduced-bore valves provide better response.
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❖ The butterfly valve’s vane is so shaped that it closes off the flow passage when it is positioned
normal to it. The vane can be rotated with a quarter-turn actuator. More like a stovepipe damper
but considerably more sophisticated, this kind of valve has no seals—the disk swings close to
but clear of the body’s inner wall. Such a valve is used for throttling applications that do not
require shutoff tighter than +1% of full flow. Body materials are cast iron, carbon steel, or
stainless steel. Mounting is lugged or welded.
❖ While a very broad range of designs is available in these products, they are limited by lack of
tight shutoff. Lined butterfly valves feature an elastomer or polytetrauoroethylene lining that
contacts the disk to provide tight shutoff. Because this seal depends on interference between
disk and liner, these designs are more limited in pressure drop. A benefit, however, is that
because of the liner, the process fluid never touches the metallic body. Thus, these products can
be used in many corrosive situations.
❖ Heavy shafts and disks characterize high-performance buttery valves, full pressure rated bodies
and sophisticated seals that provide tight shutoff. Eccentric shaft mounting allows the disk to
swing clear of the seal to minimize wear and torque. The offset disks used allow uninterrupted
sealing and a seal ring that can be replaced without removing the disk. High-performance
butterfly valves come in sizes from NPS 2 to NPS 72 or DN 50 to DN 1800 with ageless or
lugged connections. Bodies are carbon-steel or stainless steel and pressure ratings are up to
class 600 or PN 100. With their very tight shutoff and heavy-duty construction, these valves are
suitable for many process applications
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Valve Controllers
and Accessories
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Digital Positioners
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Digital Positioners
There is a general trend toward greater use of digital valve controllers on control valves for
the following reasons:
▪ Reduced cost of loop commissioning that includes installation and calibration.
▪ Using diagnostics maintain loop performance levels.
▪ By reducing the process variability, process control is improved.
▪ Offsets the decreasing mechanical skill base of instrument technicians.
The following features of digital valve controllers create most value addition to the users:
▪ Automatic configuration and calibration: The ability to configure the system by
automatic means and ability to calibrate the system easily reduces the cost of
engineering and cost of maintenance.
▪ Valve diagnostics: The valve diagnostics is important information for troubleshooting
the issues in the eld. The digital valve positioners can provide the diagnostics
information to the DCS, or to the special software tools or handheld communicators.
This information can be used to assess the health and further action can be taken very
easily
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Electropneumatic Transducers
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❖ The volume booster is normally used in ❖ The trip valves are pressure sensing in
control-valve actuators to increase the nature and are required if a special
stroking speed. These pneumatic devices valve action is required in case of
have a separate supply pressure and problems in the supply pressure. These
deliver a higher-volume output signal to valves sense the supply pressure
move actuators rapidly to their desired getting reduced or no supply pressure
positions. Special booster designs are also and cause the actuator to force the
available for use with positioners. These valve to specific position such as open,
devices incorporate a dead-band feature to close or last position. The valve
adjust their response and eliminate operation is regained back once the
instabilities. This booster, therefore, permits supply pressure is resumed. Pneumatic
high actuator stroking speeds without volume tanks provide the auxiliary
degrading the steady-state accuracy power to actuator action in case of trip
provided by positioners in the loop. valve operation.
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Limit Switches Solenoid Valves
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Calibration Procedures of
Control Valves
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Pressure to Current Transmitter (PIT)
Calibrating Pressure
1. Connect the calibrator to the instrument under test as shown in Figure.
2. Press button appropriate for current (upper display). If required, press appropriate button
again to activate loop power.
3. If necessary, press source mode button.
4. Zero the pressure module.
5. Perform checks at 0% and 100% of span and tabulate the readings “As Found” values.
6. Adjust the transmitter as necessary to minimize the deviation of As Found value and actual
value.
7. Repeat step 6 and tabulate the reading “As Left” values. If error % is within the range. Then
the calibration is performed successfully. If not repeat steps 6 and 7 until error % is within
the specified range
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Source DC
Accuracy to +0.05% Measure input signal
milliammeter
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Thank you for your attention!
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