MODULE NO.

: I-7

CONTROL VALVES &

POSITIONERS
 Every control valve must have a device to position it as required. Most
valves in a facility are positioned manually, but those referred to as control valves
usually are positioned by some power-operated device. This device may be
pneumatic, electric, hydraulic, or some combination of these.
Pneumatic Diaphragm
Most globe-type control valves are controlled by pneumatic diaphragm
actuators, which have flexible diaphragms installed between two pressure-
containing casings. The diaphragm is connected to the stem of the actuator, which
in turn is connected to the valve stem. A calibrated spring forces the stem to one
extremity. Actuators in which the spring forces the valve open are called air-fail-
open or air-to-close actuators. Actuators in which the spring forces the valve
closed are called air-fail-closed or air-to-open actuators. Typical pneumatic
diaphragm actuators are shown in Figure I-7.1A.
Most globe valves are closed by forcing the stem, and consequently the
plug, downward into the seat. An actuator that is air-fail-open has a spring that
forces the stem and diaphragm upward by the action of the top end of the spring
against the diaphragm and of the bottom end against the case. Air is applied on top
of the diaphragm to compress the spring and close the valve. Air-fail-closed
valves have a spring that acts against the case at the top end and against the stem
and diaphragm at the lower end. Air is applied below the diaphragm to compress
the spring and force the stem upward.
Pneumatic diaphragm actuators usually are operated by pressures of
between 3 and 15 psig or between 6 and 30 psig. These pressure ranges are the
same as the output of most pneumatic controllers and current-to-pneumatic
transducers, which allows direct operation in many cases. The coil spring force is
linear with respect to displacement and the force applied by the diaphragm is a
function of the effective diaphragm area and the amount of pressure applied. The
result is that stem movement is directly proportional to the pressure applied, with
only a small adjustment for friction necessary. The pressure drop across a control
valve causes a force to be applied to the stem.
This is more prevalent with single-port, top-guided globe valves than with
double-port or cage-trim balanced valves, but it exists in any valve. When the
pressure drop is large, this force is significant in relation to the spring pressure and
keeps the stem from moving linearly with changes in control pressure. The effect
of this force can be estimated and the actuator spring adjusted to compensate for
the added force. This compensation is called "bench set"; it is done by adjusting
the valve so that it travels from one extremity to the other with less than the full
range of control pressure when process pressure is not present. When the process

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pressure is present, the valve can be expected to traverse with very nearly the
entire control pressure range. For example, an unbalanced valve with a 1in port
size and 1000 psi of differential is expected to travel from closed at six psig
control pressure to open 30 psig control pressure and keep the valve closed.
Pneumatic diaphragm actuators operate directly on valve stems, which
move vertically. They also can be attached by lever arms to operate rotary-stem
valves. They are simple to understand and maintain, as well as relatively
inexpensive. They can also be operated directly by pneumatic controllers or
current-to-pneumatic transducers. For these reasons, pneumatic actuators are used
for control more often than any other type.

Pneumatic diaphragm actuators are not without disadvantages. They are

relatively low pressure devices. The diaphragm casings are limited to around 100
psig working pressure and actuator pressures over 30 to 40 psig are seldom
recommended. The available force is limited to the control pressure multiplied by
the effective area, so that these actuators cannot develop the large amount of force
required by some large valves with high pressure drops. Also, the travel of the
stem is limited by the amount of flexibility in the diaphragm. The available travel
range is from less than an inch for small sizes to about three inches for large sizes.

Piston Actuators
A piston actuator is shown in Figure I-7.1B. The piston is driven up and down the
cylinder by either pneumatic or hydraulic pressure to move the stem. The return
force can be supplied either by a compressed spring or by pressure applied to the
opposite side of the piston. The spring-return method is used with smaller
actuators because of its inherent failure position and simpler control connections.

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 Figure I-7.1A, Diaphragm Actuators, a) Lever arm linkage,
b) Adjustable-spring, c) Air-to-open, and d) Air-to-close.
The piston must supply enough force to compress the spring as well as to
stroke the valve. Because of the added force needed to compress the spring and
the difficulty of providing large enough springs, larger-sized piston actuators are
usually pressure-return types. Pressure-return piston actuators can be made fail-
safe by adding a bottle to supply return pressure if the air supply fails.
A piston actuator can move a sliding stem valve directly, by attaching the
valve stem to the actuator stem. Rotary stem valves can be actuated by translating
the linear motion into rotary motion with a rack and pinion gear or yoke assembly.
Pipe can be used for the cylinder and the piston can be constructed so that it is
rugged enough to allow use of much higher control pressures than with pneumatic
diaphragm actuators. Control pressures of up to 150 psig are commonly used with
instrument air systems and up to 1000 psig with hydraulic systems. The amount of
travel is limited only by the length of the cylinder and the stem.

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 Figure I-7.1B, Piston Actuator
Electric Actuators
Electric motors are sometimes used to actuate control valves when a reliable
pneumatic source is not available. The most common type is a geared actuator for
a rotary stem valve, as shown in Figure I-7.1C. This type of actuator is well suited
for on off control, but is not very satisfactory for modulating control. Electric
motors can be used to drive hydraulic pumps for actuation of piston-type
actuators. Hydraulic actuators with self-contained, motor-driven hydraulic pumps
and reservoirs are available, or a separate hydraulic supply package can be used
for several valves.

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 Figure I-7.1C, Electric Actuator for Motorized Valve

Control valves are manufactured in several body styles, which look quite
different from each other. Each of these designs is appropriate for use in some
circumstances, and often more than one type will be satisfactory. These types are
discussed below:

1. Globe-Shaped Valves
Globe-type control valves are those most commonly used in the process
industry. This design lends itself to variations of internal geometry that make them
useful in a wide variety of applications. Globe control valves are available with
body sizes as small as 1/2 in and trims as low as 1/4 in or less. They are also
available from some manufacturers in 12 in or larger sizes.
Most types of valves derive their names from their physical appearance.
The globe valve is no exception, in that both its body and its plug are somewhat
spherical in shape. Figure I-7.2A shows a typical top-guided globe valve. The
identifying characteristic is that a plug moves vertically so that flow is regulated
by the area between the plug and a circular seat. The plug and the seat are
machined and sometimes honed to form a good seal. Resilient material can be

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used for the seat to form an even better seal. Various body geometry and plug
shapes give different flowing characteristics.
The plug is held in position by the stem. The stem is moved up or down to
provide throttling by opening or closing the valve. The stem slides through guides
that keep it lined up with the seat. A single guide in the top-works of the valve is
adequate for many applications. Figure I-7.2B shows a top-and-bottom-guided
globe valve. The third important type of guiding is cage guiding, in which the
plug travels inside a machined sleeve and closes holes in the sleeve to control
flow. Figure I-7.2C shows a cage-guided globe valve.
The number of ports in a globe valve refers to the number of orifices
through which flow may pass. Most valves are either single or double ported
valves. Cage-guided valves are considered single-ported, even though there are
usually several passages through the cage. The trim of a control valve consists of
the internal parts that come in contact with the fluid; the stem, guide, plug, and
seat.
Single-ported, top-guided valves, are the simplest of the globe valves. They
are fewer cavities for solids to collect and it is easier to replace the trim parts than
in other types. The single-seating surface is convenient for machining to achieve
tight shutoff.
The upstream pressure acts on one side of the single-ported valve plug,
while the downstream pressure acts on the other. The actuator must supply enough
force to overcome this pressure imbalance. If the pressure drop or the plug area is
large, the force required from the actuator may exceed practical limitations.
Double-ported valves, have two plugs arranged so that the pressure drop acts
upward on one plug and downward on the other. Because of this counteraction,
the actuator needs to develop only the thrust required to overcome friction and the
imbalance caused by the stem area.
Cage-guided valves allow balanced operation because a passage through the
plug, as shown by Figure I-7.2C, equalises the pressure above and below the plug.
The plug is raised or lowered to block a portion of the holes in the cage and thus to
control flow. The force required for pressure drop is supplied by the rigidity of the
cage and plug and very little of it by the stem and actuator. The actuator force
required is about the same as for double-ported valves.

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Figure i-7.2A, A Top-guided, Single-port Globe Valve

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Figure I-7.2B, Top and Bottom-guided
Double-port Globe Valve

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 Figure I-7.2C, Cage-guided Globe Valve

Three-way Globe Valves are available for combining or splitting process fluids.
Figure I-7.2D, shows Cage-guiding three-way globe valve where, the pressure
drop forces are balanced. Three-way globe valves are sometimes used for flow
diversion.
Angle globe valves are sometimes used for piping convenience; they have
good flow characteristics in either direction. A major use for angle valves is for
large pressure drops where cavitation is possible. For this application, the flow
must be into the side and out away from the stem. While cavitation damage may
occur, it will be mostly to the valve outlet and downstream piping, rather than to
the plug and stem.
Variable-choke valves are a form of angle valve, are used to control two-
phase flow from wellheads and in applications with large flow rates.

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 Figure I-7.2D, Cage-guided Three-way Globe Valve

2. Ball Valves

Ball valves feature a spherical plug that is rotated within a similarly shaped
chamber, as shown in figure I-7.2E. The ball is bored with a hole that can be lined
up with the pipe openings, perpendicular to the openings or somewhere in
between. If the hole through the ball is the same size as the inside diameter of the
pipe, it is called full port or full bore. If the hole is smaller than the inside diameter
of the pipe, it is called reduced port or reduced bore. Full-port ball valves are used
when an object such as a pipeline pig or scraper must pass through, or when even
a small pressure drop cannot be tolerated. Reduced-port valves have bodies that
are tapered between the pipe and the ball, so that the pressure drop is small; they
are satisfactory in most applications.
Ball valves are either floating ball or trunnion mounted. Floating ball valves
have a slot in the ball perpendicular to the bore.
The stem has flats machined onto it to fit into the slot. When the valve is
closed, the line pressure forces the ball against the downstream seat to cause tight
shutoff. The trunnion-mounted ball is rigidly attached to the stem and has a pin on
the bottom of the ball that rides in a bearing. This ball does not move into the seat
when closed. Floating ball valves are seal well on simple seats and are intrinsically
fire-safe. They require more torque than trunnion-mounted balls, and thus a larger
actuator for opening when full pressure differential is applied.

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 Trunnion-mounted balls require spring-loaded seals and can use smaller
actuators.

Figure I-7.2E, Ball Valve

3. Butterfly Valves

Butterfly valves have a round disk for regulating flow, as shown in figure I-
7.2F. The disk is attached to a shaft, one end of which rests in a bushing, with the
other end brought out through a seal assembly for actuator attachment. The disk
can be rotated perpendicular to the pipe to stop flow, parallel to the pipe to
maximise flow, or in between to regulate flow. Manufacturers offer variations of
the basic disk-shape which enhance throttling characteristics, provide shutoff
capabilities, or minimise required torque.
Butterfly valves are used often in fire water systems and utilities, and as
throttling valves on compressor suction lines. They are particularly suitable for
low pressure drops in large lines.

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4. Cam-flex Valves

Figure I-7.2G, Cam-flex Valve

Cam-flex valve, shown in Figure I-7.2G, is a quarter-turn valve that

functions like a characterised ball valve. It has the advantage of a cam action that
applies greater sealing force when closed. The actuator has a cam, which can
characterise the flow as required.

Flow Characteristics
The inherent flow characteristic of a control valve is the relationship of the
flow rate through the valve to the valve travel while a constant pressure drop is
maintained across the valve body. The installed flow characteristic is the
relationship of the flow rate to valve travel, as the pressure drop across the
valve varies as a result of the many factors involved in the process.
The objective in choosing an inherent flow characteristic for the valve is to
make the installed flow characteristic as nearly linear as possible. Figure I-7.2H
shows globe valve plugs for the three main inherent flow characteristics.

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Figure I-7.2H, Globe Valve Plugs for the
Three Main Inherent Flow Characteristics

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Linear, with the linear inherent characteristic, the flow is directly proportional to
the valve stem movement. That is to say, at 50 percent stem movement, the Cv is
50 percent of maximum and at 80 percent of movement, the Cv is 80 percent of
maximum. Linear valves are best when the pressure drop across the valve is fairly
constant, no matter what the flow rate. Linear trim is usually used for flow control,
liquid pressure control, and modulating liquid level control.

Equal Percentage, the equal percentage inherent characteristic means that the C.
changes in proportion to the percentage increment of the valve travel. This
characteristic means that valve movements near the seat cause relatively small C,
changes, while valve movements near the wide open position cause large C,
changes. This characteristic is useful when the available pressure drop decreases
with increased flow, or when the effect on the process is diminished as the flow
rate increases. Gas pressure control loops and temperature loops usually fall into
this category.
Quick Opening, the quick-opening inherent characteristic is that in which the
flow rate changes more rapidly at low travels than when the valve is nearly open.
This characteristic is useful when a rapid rise to near maximum flow is needed,
such as in applications in which it is necessary to respond quickly to pressure
surges and on-off level control. This characteristic could be useful for a liquid-
control valve in situations in which solids may be present. A simple disk covering
a flow nozzle will obtain this characteristic. Quick opening valves are commonly
used for self-actuated pressure regulators, relief valves, and on/off applications.

Fluid Flow Direction,

Valve manufacturers usually recommend a direction for fluid flow through their
product that is often indicated by an arrow that is cast on the body. Most valve
designs have better flow characteristics with the flow going through the port
toward the stem, thus providing an opening force on the plug. General exceptions
are those valves in which liquid cavitation or flashing can be anticipated.
Cavitation and flashing cause increased wear on valve parts downstream of the
port, hence it is usually better to flow away from the stem and stem guides.

Valve Body Maintenance

Avoid personal injury or damage to property from sudden release of pressure or
uncontrolled process fluid. Before starting disassembly:
 Shut off operating lines to the actuator,
 Isolate the valve from the process,
 Release process pressure, and
 Vent the actuator loading pressure.

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 Valve parts are subject to normal wear and must be inspected and replaced as
necessary. Inspection and maintenance frequency depends on the severity of
service conditions. The following includes instructions for trim maintenance, and
bellows seal replacement.
Whenever a gasket seal is disturbed, by removing or shifting gasketed parts, a
new gasket should be installed upon re-assembly. This is necessary to ensure a
good gasket seal since the used gasket may not seal properly.

Trim Maintenance
key numbers indicated in this section are referenced in figure I-7.3A
Disassembly
1. Remove the actuator and the bonnet according to steps 1 through 5 of the
replacing packing portion of this Doc.
2. Packing parts can be removed if desired. Replace these parts as described in the
replacing packing procedure.
3. Lift the valve plug and stem assembly, seat ring retainer and gaskets out of the
valve body and set them on a protective surface. With the assembly out of the
body, slide the seat ring retainer and bushing (keys 3 and 26) up over the valve
plug and stem. if the valve plug is to be reused, protect the valve plug seating
surface to prevent scratches.
4. Remove the seat ring and seat ring gasket (keys 9 and 13).
5. Inspect parts for wear or damage which would prevent proper operation of the
valve. Replace or repair trim parts according to the following lapping metal
seats or valve plug maintenance as appropriate.

Lapping Metal Seats

 With metal-seat constructions, seating surfaces of the valve plug and seat ring
(key 2) can be tapped for improved shutoff. (Deep nicks should be machined
out rather than ground out.) Use a commercial lapping compound.
 Assemble the valve to the extent that the seat ring retainer is in place and the
bonnet is bolted to the body. A simple handle can be made from a piece of
strap iron locked to the valve plug stem with nuts. Rotate the handle alternately
in each direction to lap the seats.
 After lapping, remove the bonnet and clean the seat surfaces. Completely
assemble as described in the assembly portion of the trim maintenance
procedure and test the valve for shutoff. Repeat the lapping procedure if
leakage is still excessive.

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Valve Plug Maintenance
1. Remove the valve plug (key 2) according to the disassembly portion of the trim
maintenance procedure.
2. To replace the valve stem (key 7), connection stud (key 24, figure 6), or tip
(key 30) drive out the groove pin (key 8 and 31, if used) and unscrew the stem,
stud, or tip from the valve plug. A cap screw (key 32) is used to secure the tip
(key 30) to the valve plug guide (key 27) on the 3 and 4 inch port diameter
valve bodies.
3. Screw the stem, stud, or tip into the valve plug. Drill through the stem or stud,
using the hole in the valve plug as a guide. Remove any chips or burrs and
drive in a new groove pin to lock the assembly. On a bellows seal bonnet
assembly, thread the new stem into the stud.
Assembly
1. Install the seat ring gasket (key 13), and replace the seat ring (key 9).
2. Slide the valve plug assembly [and the valve plug guide, disk retainer, and disk
(keys 27, 28, and 29) if used] into the seat ring retainer (key 3).

3. Install the seat ring retainer with the valve plug assembly on the top of the seat
ring, ensuring that the seat ring retainer slips onto the seat ring properly. Any
rotation orientation of the seat ring retainer with respect to the body is
acceptable.

4. Place the seat ring retainer gasket or shim, spiral wound gasket, and bonnet
gasket (keys 11 or 25, 12, and 10) on the shoulder of the seat ring retainer.

5. Mount the bonnet on the body and complete the assembly according to steps 9
through 14 of the replacing packing procedure, omitting steps 11 and 12 if new
packing is not being installed.

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 Figure I-7.3A, Globe Valve Body
Bellows Seal Replacement

On bellows seal bonnets, the stem must not be rotated, or damage to the bellows
will result.

Refer to figure I-7.3B except where indicated.

1. Exhaust all actuator pressure, if any was applied, and disconnect the actuator
supply and any leak-off piping. Remove the cap screws in the stem connector,
and separate the two halves of the stem connector.

2 Remove the locknut (key 15), and remove the actuator from the bonnet (key 1).
Loosen the packing flange nuts (key 5) so that the packing (key 6) is not tight
on the valve stem (key 7, figure I-7.3A). Remove any travel indicator parts and
stem locknuts from the valve stem threads.
3 Remove the hex nuts (key 16, figure I-7.3A), and lift off the bonnet. If the
bellows seal adapter, bellows seal (keys 17 and 20), and valve plug assembly
(key 2, figure I-7.3A) come out with the bonnet, separate them from the bonnet
by pulling them free.

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4 Screw the stem locknuts onto the valve stem, and lock the nuts together. Hold a
wrench on the flats of the shaft extending out of the top of the bellows seal
assembly (key 20), and use a wrench on the stem locknuts to unscrew the valve
plug stem from the bellows seal assembly.
5 Remove the cap screws (key 23) from the bellows seal adapter.
6 Unscrew the bellows seal assembly from the connection stud (key 24). Use a
wrench on the flats of the shaft extending out of the top of the bellows seal
assembly, and on the flats of the connection stud near the valve plug end.
7 Install the new bellows assembly by screwing it onto the connection stud.
Make sure that the travel stop (key 19) is in place. Also make sure the new
gaskets and anti-rotator are in place in the bellows seal adapter (keys 21, 18,
and 17).
8 Bolt the bellows seal assembly to the bellows seal adapter with the cap screws
(key 23).
9 Hold a wrench on the flats of the shaft extending out of the top of the bellows
seal assembly, and screw the valve plug stem into the shaft.
10 Install all new gaskets between the bellows seal, adapter and the body, and
between the bellows seal adapter and the bonnet (key 22). Mount the bonnet on
the body. Install and tighten the nuts (key 16, figure I-7.3A).
11 Mount the actuator on the valve body according to the procedure in. the
appropriate actuator instruction manual.

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 Figure I-7.3B, Bellows Seal Bonnet

Actuator Bench Set

The bench set pressure range is used to adjust the initial compression of the
actuator spring with the valve-actuator assembly "on the bench." The correct
initial compression ensures that the valve-actuator assembly will function properly
when it is put in service and the proper actuator diaphragm operating pressure is
applied.
The bench set range is established with the assumption that there is no packing
friction. When attempting to adjust the spring in the field, it is very difficult to
ensure that there is no friction being applied by "loose" packing.
Accurate adjustment to the bench set range can be made during the actuator
mounting process, by making the adjustment before the actuator is connected to
the valve.
If you are attempting to adjust the bench set range after the actuator is connected

20
to the valve and the packing tightened, you must take friction into account. Make
the spring adjustment such that full actuator travel occurs at the bench set range
(a) plus the friction force divided by the effective diaphragm area with increasing
diaphragm pressure or (b) minus the friction force divided by the effective
diaphragm area with decreasing diaphragm pressure.

Adjustment Steps
1. Monitor actuator loading-pressure carefully when making adjustments. Do not
exceed the maximum pressure specifications of either the loading regulator or
the actuator casings,
2. Each actuator spring has a fixed pressure span, Changing the spring
compression shifts the span up or down to make valve travel coincide with the
pressure range,
3. Turn the spring adjustor (key 74, figure I-7.4A), into the yoke to shift the span
up or turn the spring adjustor out of the yoke to shift the span down.

4. If the actuator has a side-mounted hand-wheel assembly (manual actuator),

clockwise hand-wheel rotation closes the valve,
5. For successful operation, the actuator stem and valve plug stem must move
freely in response to the loading pressure change on the diaphragm.

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 Figure I-7.4A, Valve Actuator Assembly
Actuator Maintenance

Actuator parts are subject to normal wear and must be inspected and replaced
when necessary. The frequency of inspection and replacement depends on the
severity of service conditions.
This procedure describes how the actuator can be completely disassembled and
assembled. When inspection or repairs are required, disassemble only those parts
necessary to accomplish the job; then, start the assembly at the appropriate step.
Key numbers refer to figure I-7.4A.
Disassembly
1 Bypass the control valve. Reduce the loading pressure to atmospheric, and
remove the tubing or piping from the connection in the top of the yoke (key

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 73). For a top-loaded construction, also remove the piping or tubing from the
connection in the upper diaphragm casing (key 1).
2 Thread the spring adjustor (key 74) out of the yoke (key 73) until all spring
compression is relieved.
3 If necessary, remove the actuator from the valve body by separating the stem
connector (key 31) and removing the yoke locknut.
4 Unscrew the spring adjustor (key 74) from the actuator stem (key 144). Also
lift the spring seat and spring (Key 19 and 18) out of the yoke.
5 Remove the diaphragm casing cap screws and nuts (keys 13 and 14), and lift
off the upper diaphragm casing (key 1).
6 Remove the following connected parts: the diaphragm (key 3), upper
diaphragm plate (key 4), spacer (key 2), cap screw (key 12), and actuator stem
(key 144). Be careful when pulling the threads of the actuator stem through the
seal bushing (key 7) to avoid damaging the 0-rings (key 8).
7 Remove the cap screw (key 12) to separate the parts of this assembly.
8 To remove the seal bushing, remove the snap ring (key 72), and lift out the
bushing.
9 Remove cap screws (key 30), and take off the lower diaphragm casing (key 64)
and the gasket (key 70) can be removed, if necessary.

Assembly
1. Coat the 0-rings (key 70) with lubricant (key 237 or equivalent). Place a new
gasket or 0-ring (key 70) on the yoke (key 73). Position the lower diaphragm
casing (key 64) on the yoke, align the holes, and insert and tighten the cap
screws (key 30). If down travel stops (key 77) were removed, insert and tighten
them.
2. Coat the 0-rings (keys 8 and 9) with lubricant (key 237 or equivalent) and place
the 0-rings in the seal bushing (key 7).
3. Fill the seal bushing with lubricant (key 237 or equivalent), slide the bushing
into the yoke (key 73), and install the snap ring (key 72).
4. Assemble the actuator stem (key 144), lower diaphragm plate (key 71),
diaphragm (key 3), upper diaphragm plate (key 4), and the travel stop cap
screw and spacer (keys 12 and 2). Place this assembly in the actuator. Take
care when pushing the actuator stem through the seal bushing so that the
threads do not damage the 0-rings.

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5. Install the upper diaphragm casing (key 1), and secure with cap screws and
nuts (keys 13 and 14). Tighten evenly, using a criss-cross pattern to ensure a
proper seal.
6. Install the actuator spring (key 18) and spring seat (key 19). Apply lubricant
(key 237 equivalent) to the threads of the actuator stem and to the surface of
the spring adjustor (key 74) that contacts the spring seat. Thread the spring
adjustor on the actuator stem.
7. Mount the actuator on the valve in accordance with the installation procedures.

Actuator’s Stroke

Actuator’s stroke length and force must be sufficient to operate the valve and the
actuator’s stroke time must be considered to ensure that the valve can control the
system transients. Figure I-7.5A shows the valve yoke assembly.

Figure I-7.5A, Globe Valve

Yoke Assembly

Loading Connection
1. Connect the loading pressure piping to the NPT female connection in the top of
the actuator yoke.
2. Keep the length of tubing or piping as short as possible to avoid transmission
lag in the control signal. If an accessory (such as a volume booster or valve

24
 positioner) is used, be sure that the accessory is properly connected to the
actuator.
3. Cycle the actuator several times to check that the valve stem travel is correct
and that the travel occurs when the correct pressure range is applied to the
diaphragm.
4. If valve stem travel is incorrect, refer to the Travel procedure in the
Adjustments section.
5. If the pressure range is incorrect, refer to the Spring procedure in the
Adjustments section.
Adjustments

a) Travel

Make travel adjustments when the motion observed during actuator travel is
different from the travel stamped on the actuator nameplate. If the actuator
mounting procedure was followed correctly, this adjustment should not be
necessary.

When adjusting travel of a direct-acting (push-down-to-close) valve, apply a

low supply pressure to the actuator diaphragm casing. This moves the valve plug
off of the seat, reducing the chance of damaging the valve plug or seat during
adjustments.

1. Back the stem locknuts and indicator disk away from the stem connector, and
slightly loosen the stem connector cap screws. (Do not use wrenches or other
tools directly on the valve stem. Damage to the stem surface and
subsequent damage to the valve packing might result).

2. Tighten the locknuts together, use a wrench on these locknuts, and screw the
valve stem either into the stem connector to lengthen travel or out of the stem
connector to shorten travel.

3. Cycle the actuator to check the travel. If travel is not equal to the specified
travel, adjust and check travel until correct. Tighten the stem connector cap
screws when correct travel is obtained.

4. Raise the travel indicator disk by threading the stem locknuts against the stem
connector.

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Valve Leakage Check and Packing Replacement.
Avoid personal injury or damage to property from sudden release of pressure or
uncontrolled process fluid. Before starting disassembly:
 Shut off operating lines to the actuator,
 Isolate the valve from the process,
 Release process pressure, and
 Vent the actuator loading pressure.
Valve parts are subject to normal wear and must be inspected and replaced as
necessary. Inspection and maintenance frequency depends on the severity of
service conditions. The following includes instructions for packing lubrication,
and packing maintenance.
Whenever a gasket seal is disturbed, by removing or shifting gasketed parts, a
new gasket should be installed upon re-assembly. This is necessary to ensure a
good gasket seal since the used gasket may not seal properly.

Packing Lubrication
If a lubricator or lubricator/isolating valve is provided for
PTFE/composition or other packing that require lubrication, it will be installed in
place of the pipe plug (key 14, figure I-7.4A). Use a good quality silicon-base
lubricant. To operate the lubricator, simply turn the cap screw clockwise to force
the lubricant into the packing box. The lubricator/isolating valve must first be
opened and then closed after lubrication is completed.

Packing Maintenance
This procedure covers only PTFE V-ring and PTFE/composition packing.
For spring-loaded single PTFE V-ring packing, the spring (key 8, figure I-
7.6A) maintains a seating force on the packing. If leakage is noted around the
packing follower (key 13, figure I-7.6A), check to be sure the shoulder on the
packing follower is touching the bonnet.
If the shoulder is not touching the bonnet, tighten the packing flange nuts,
until the shoulder is against the bonnet. If leakage cannot be stopped in this
manner, proceed to the replacing packing procedure.

26
 If there is undesirable packing leakage with other than spring-loaded
packing, first try to limit the leakage and establish a stem seal by tightening the
packing flange nuts.
If the packing is relatively new and tight on the stem, and if tightening the
packing flange nuts does not stop the leakage, it is possible that the valve stem is
worn or nicked so that a seal cannot be made. The surface finish of a new valve
stem is 4 micro-inches. If the leakage comes from the outside diameter of the
packing, it is possible that the leakage is caused by nicks or scratches around the
packing box wall. If performing any of the following procedures, inspect the valve
stem and packing box wall for nicks and scratches.

Adding Packing Rings

When using packing with a lantern ring (key 8, figure I-7.6A), it is possible to
add packing rings above the lantern ring as a temporary measure without
removing the actuator from the valve body.
1. Isolate the control valve from the line pressure, and release pressure from the
valve body.
2. Remove the packing flange nuts and lift the packing flange and follower away
from the valve body.

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3. It may be possible to dig out the old packing rings on top of the lantern ring,
but use care to avoid scratching the valve stem or packing box wall. Clean all
metal parts to remove particles that would prevent the packing from sealing.
4. If split-ring packing is being added, spread the rings over the stem and slide the
rings into the packing box. Alternate the position of the splits to avoid creating
a leak path. If solid-ring packing is being added, remove the stem connector
and slip the rings over the end of the valve stem.
5. Replace the packing flange and packing follower. Tighten the packing flange
nuts only far enough to stop leakage under operating conditions.

Replacing Packing
1. Isolate the control valve from the line pressure, and release pressure from the
valve body.
2. Disconnect the operating lines from the actuator and any leak-off piping from
the bonnet. Disconnect the stem connector and then remove the actuator from
the valve body by unscrewing the yoke locknut.
3. Loosen the packing flange nuts so that the packing is not tight on the valve
stem. Remove any travel indicator parts and stem locknuts from the valve stem
threads.
4 When lifting the bonnet be sure that the valve plug and stem assembly remains
in the body and on the seat.
5. Unscrew the cap screws or hex nuts that bolt the bonnet and body together and
carefully lift the bonnet off the valve stem. If the valve has a bellows seal
bonnet, separate the bonnet from the bellows seal adapter.
6. If the valve plug and stem assembly starts to lift with the bonnet, use a brass or
lead hammer on the end of the stem and tap it back down. Set the bonnet on a
protective surface to prevent damage to the bonnet gasket surface.
7. Remove the bonnet gasket, and cover the opening in the valve body to protect
the gasket surface and to prevent foreign material from getting into the body
cavity.
8. Remove the packing flange nuts, packing flange, upper wiper, and packing
follower. Carefully push out all the remaining packing parts from the body side
of the bonnet using a rounded rod or other tool that will not scratch the packing
box wall. Clean the packing box and the metal packing parts.
9. Inspect the valve stem threads and the packing box surfaces for any sharp
edges, which might cut the packing. Scratches or burrs could cause packing

28
 box leakage or damage to the new packing. If the surface condition cannot be
improved by light sanding, replace the damaged parts.
10.Remove the covering protecting the body cavity and install a new bonnet
gasket making sure the gasket seating surfaces are clean and smooth. Then
slide the bonnet over the stem and onto the stud bolts.
11.Lubricate the bolting and install it, using accepted bolting procedures during
tightening so that the body-to-bonnet joint can withstand test pressures and
application service conditions.
12.Install new packing and the metal packing box parts according to the
appropriate arrangement. If split-ring packing is being added, alternate the
position of the splits to avoid a leak path. Place a smooth-edged pipe over the
valve stem and gently tap each soft packing part into the packing box, being
sure that air is not trapped between adjacent soft parts.

13 Slide the packing follower, upper wiper, and packing flange into position.
Lubricate the packing flange studs and the faces of the packing flange nuts.
Install the packing flange nuts.
14 For spring-loaded PTFE V-ring packing, tighten the packing flange nuts until
the shoulder on the packing follower contacts the bonnet.
15 Mount the actuator on the valve body and reconnect the actuator and valve
stem according to the procedure in the appropriate actuator instruction manual.

29
 Figure I-7.6B, Valve Plain Bonnet Showing Packing Details

Transducers

Control valves are usually pneumatic devices, while controllers may be

either pneumatic or electronic. When an electronic controller is to be used with a
pneumatic control valve, a transducer is used to convert the electronic signal to a
pneumatic signal. These transducers are commonly called I to Ps or written I/P
from the common symbols for current and pressure. The most common signal
levels are 4 to 20 ma input and 3 to 15 psig output, but can be as required by the
controller and the control valve.

The I/P transducer can be combined with a positioner, usually called an

electronic positioner. When an electronic positioner is needed, an I/P transducer
and a pneumatic positioner can be used instead. In some applications engineers
prefer to mount a transducer off the valve to isolate the electronics from process
vibration.

30
Principle of Operation
As illustrated in figure I-7.9B, the schematic diagram of I/P transducer,
assume that: the transducer is direct-acting, an increase in the dc signal to the coils
increases the magnetic field around the coils. This field increases the magnetic
strength in the armature and the magnetic attraction across the air gap between the
armature and the pole pieces.
The pole pieces are already polarised by the permanent magnet. The
armature polarity is as shown in the schematic. The magnetic attraction will
therefore be downward at the nozzle end and upward at the feedback bellows end,
resulting in a torque that rotates the armature about the fixed torsion rod to cover
the nozzle. The resulting restriction produces an increased pressure in the nozzle,
in the upper chamber of the relay, and in the feedback bellows. The relay responds
to the increase in nozzle pressure to increase the output pressure to the actuator
and control valve. The increased pressure in the feedback bellows creates a force
that acts on the armature to move it back to an equilibrium position. In this way,
the new nozzle pressure is compared to the input current by the force-balance
principle.
The relay operates in the following manner. The nozzle pressure acts on the
large top diaphragm to force the centre spacer assembly (mounted between the
two diaphragms) downward against the valve plug, closing the exhaust port and
opening the supply port. Supply air then flows through the open port to the output
load. The out t pressure continues to increase until the relay diaphragm assembly
is pushed back to its original position by the force of the pressure acting on the
small diaphragm. When this occurs, the valve plug is closed again.
When a decreasing dc signal is received, the magnetic attraction across the
air gap is reduced. The armature rotates to uncover the nozzle and decrease the
pressure in the nozzle, relay, and feedback bellows. The relay diaphragm assembly
moves upward, and the exhaust port opens to bleed the output pressure to
atmosphere.
The output decreases until the diaphragm assembly is forced back to its
original position and the exhaust port is closed again. The reduced pressure in the
feedback bellows diminishes the force to return the armature to the equilibrium
position.
Reverse-acting transducers operate in a similar manner, except that when
the dc input signal increases, the output pressure from the relay decreases.
Conversely, a decreasing input signal increases the output pressure.

31
 Figure I-7.9B, Schematic Diagram of I/P Transducer Principle.

Calibration and Adjustments

To perform any calibration or adjustments of the I/P transducer, which requires

removal of the cover, these steps to be performed first:

 Disconnect the electrical signal from the transducer.

 Remove the transducer to a non-hazardous area.
 Perform calibration or adjustment procedures.
 Reinstall the transducer, and ensure the cover is secured before turning on the
electrical signal.
Adjustments
 With the filter regulator adjusted to provide the proper supply pressure to the
transducer.
 The zero adjustment is used to set the output pressure so that it corresponds to
the proper value of the input signal. For example, if the output range is 3 to 15
psig and the input range is 4 to 20 mA dc and the unit is direct-acting, the zero
adjustment would be used to set the output pressure at 3 psig when the input
signal is 4 mA.

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 The span adjustment is used to set the span of the output pressure so that, full
output pressure change results from a full change in the input signal. In this
example, the output pressure change would be 12 psi as the output pressure
goes to 15 psig, when the input signal is changed from 4 to 20 mA.
 A span adjustment will affect the zero. Therefore, any span adjustment should
be followed by a zero adjustment.

Figure I-7.9C,
I/P Transducer
Zero and Span
Adjustments

Calibration
The following calibration procedure is for a transducer with a 4 to 20 (mA) dc ,
input signal range and a 3 to 15 psig output range.
1. Check the supply pressure to ensure it agrees with the minimum pressure on
the transducer nameplate,
2. Adjust the input current to 4.00 mA dc,
3. Turn the zero screw until the output pressure is 3.00 psig ± 0.09 psig,
4. Adjust the input to 20.00 mA dc,
5. If the output pressure is less than 14.91 psig, turn the span screw clockwise to
increase the span. If the output pressure is greater than 15.09 psig, turn the span
screw counter-clockwise to decrease the span.
6. Repeat steps 2 through 5 until the output pressure is within one-third of the
accuracy limits at 4 and 20 mA dc. One-third of the accuracy limits for a 3 to
15 psig output range is 1/3 x (±0.0075) x (15.00 - 3.00) = ±0.03 psig. Calibrate
for maximum accuracy at the target end points [3.00 and 15.00 psig. This
allows for error at other calibration points in between.
7. Run the transducer through three calibration cycles before recording data. The

33
 cycles should be run from exactly 4.00 to 20.00 mA dc in a slow ramping
fashion.
8. After returning from 20.00 mA dc during the last exercise cycle, move back
upscale to the midpoint (12.00 mA dc) and record the first data point.
9. Record at the other calibration points desired by moving upscale to 20.00 mA
dc then downscale to 4.00 mA dc, then back upscale to 12.00 mA dc.
10.After completing the calibration cycle and recording data, verify that all data is
within ± 0.75% accuracy limits. If not, the transducer may need to be
recalibrated to move the end points slightly to bring the entire calibration curve
within the accuracy limits.

Positioners and Boosters

A valve positioner is a device that mechanically monitors the valve position and
supplies the correct pressure to drive the valve to coincide with the control signal
(see Figure I-7.10A). Positioners can reduce the amount of flow required from the
controller or transducer, drive actuators that require different pressure ranges than
the available control signal, and correct for the effects of process dynamics on the
valve position.
A value booster reduces the amount of flow required from the controller or
transducer and can speed the valve action, but cannot correct for process
dynamics. The input and output pressures are usually the same. Figure I-7.10B
shows typical boosters.
Valve positioners should be used when:
1) Piston actuators are used for control.
2) The actuator requires pressure range different from the control range.
3) Multiple valves with, different pressure ranges are controlled by a single
controller (split range).

Boosters should be used when:

1) The pneumatic control line is long enough to cause excessive delay in valve
operation.
2) The controller or transducer does not provide enough volume to move the
valve at the required speed.

34
Figure I-7.10A,
Valve Positioner

35
 Figure I-7.10B, Valve Booster: a) Low Capacity Booster,
b) High Capacity Booster, and c) Typical Valve Booster Circuit

Valve Positioner Alignment

The purpose of alignment is to ensure the correct mechanical position of
parts so the valve positioner can be calibrated. It is necessary to provide the
appropriate supply pressure, and you must be able to manually set the input signal
at the midpoint of the desired input signal range.
See figure I-7.10C. The flapper assembly can be positioned by hand to
different settings on the beam assembly or by using a screwdriver in the slot of the
nylon adjustment gear G. The beam (F) is leveled at the factory prior to shipment.

36
Once the beam is leveled, no future leveling should be required unless the pivot
pin (C) or the locking hex nut (B) are changed or if the bellows assembly or range
spring are replaced or the valve positioner is to be set up for split range operation.
To level the beam, proceed as follows:
In the following steps, if it is not possible to attain the required output pressure
when adjusting a pivot point, adjust one of the other pivot points slightly. Then,
repeat the original pivot adjustment. Continue this process until the required
output pressure can be attained.
1. Stroke the actuator in its mid-travel position with a hand-wheel or a manual
loader. Referring to figure 4, lift the rotary shaft arm (key 2) so that the index
marks on the rotary shaft arm and case indicate the mid-travel position as
shown in figure 7, or lift the rotary shaft arm so that the slot in it is parallel
with the connector arm (key 48). Then, position the travel pin (key 60) so that
it is perpendicular to the arm and matches the total actuator travel on the rotary
shaft arm. Tighten the locking nut (key 62).
2. Refer to figure 16. Loosen the locknut (key 71) and turn the nozzle (key 18)
clockwise to its lowest position. Then screw the nozzle out (counter-clockwise)
2 turns and tighten the locknut.
3. Remove any loading pressure and/or disengage any hand-wheel used to
position the actuator. Connect the necessary tubing from the valve positioner
output to the actuator pressure connection.
4. Connect the input to the valve positioner and set the input signal value at
midrange. For example, valve positioner with a 3 to 15 psig input signal range,
set the value at 9 psig. Then apply supply pressure to the valve positioner.
5. Move the flapper assembly to zero on the beam scale. Loosen the follower
assembly screw locknut (key 19H, figure 18) and adjust the follower assembly
screw (key 1 9G, figure 18) to yield an output pressure equal to the mid-point
value of the output pressure range. Tighten the locknut.
6. Move the flapper assembly to position 10 on the direct-acting side of the beam
scale. Loosen the bellows assembly locknut (B, figure 12) and adjust the
bellows pivot pin (key 30, figure 16) to yield an output pressure equal to the
mid-point value of the output pressure range. Tighten the locknut.

7. Move the flapper assembly to the left to position 10 on the reverse acting side
of the beam. Loosen the locknut and adjust the beam pivot pin to provide an
output pressure equal to the mid-point value of the output pressure range .
Tigten the locknut.

37
8. Repeat steps 5,6 and 7 to optimise alignment.

Figure I-7.10C,
Valve Positioner
Partial View

Figure I-7.10D,
Electro-Pneumatic
Valve Positioner
Schematic.

38
Quick Exhaust Valves

Quick exhaust valves provide better than three times the piston speed. In either
direction with double acting cylinders. As the return stroke with single acting
cylinders. Mounted at the cylinder port, exhaust air is “dumped”

Figure I-7.11A Quick Exhaust Valve General View

39
Pneumatic Switching Valves
To understand the purpose of using these types of valves and its construction
details; INVALCO model CDM is an example which is a diaphragm operated
pilot valve for pneumatic or hydraulic control. The unit is equipped with one, two
or three snap-acting 3-way MICRO VALVES to provide on-off output to one or
more controlled circuits.

Figure I-7.12A, INVALCO Switching Valve

OPERATION
Process pressure is applied to the upper diaphragm chamber, causing the stem to
lower against the spring. When the upper drive collar has been dropped
sufficiently, the MICRO VALVE will snap, thereby reversing the control circuit.
As process pressure decreases, the lower drive collar will raise, contacting the
toggle arm which causes the MICRO VALVE to snap to its' "normal" position.

ADJUSTMENT
Operating adjustments are very simple on the CDM pilot. The range spring is
fixed and requires no adjustment. The process pressure required to trip and release
the MICRO VALVE will depend upon the spacing of the drive collars. The
adjustable drive collars provide a convenient means of adjusting the span of output

40
valve action within the operating range. Tripping pressure can be adjusted from
approximately 6 to 20 psi; with release pressure varying from approximately 2 to
8 psi.

Figure I-7.12B, INVALCO Switching Valve Partial View.

Where manual reset is required, it is necessary merely to remove one of the

adjustable drive collars. The CDM pilot lends itself to lock-up or alarm service,
since either application or loss of process pressure can cause the MICRO VALVE
to trip, with manual reset required by removing either the lower or upper drive
collar. The clear plastic cover permits visual indication of the MICRO VALVE
position as well as the approximate value of process pressure.
Differential pressure control is another process variable, which can cause
actuation of the MICRO VALVE. In this application, the lower process pressure is
applied below the diaphragm with the higher pressure above the diaphragm. The
MICRO VALVE will now be tripped by a change in the differential between two
process pressures. In this application, the maximum static pressure applied to
either side of the diaphragm must be limited to 100 psig.

41
Figure I-7.12C shows INVALCO switching valve assembly, the following table
list the parts description:

Ite Description Item Description

m
1 Upper diaphragm case 14 Set screw
2 Flexioc nut ¼” – 28 15 Case
3 Washer 16 Cover
4 Diaphragm 17 Cover screw
5 Fill Hd. Screw 18 O-ring
6 Hex nut 19 Spacer
7 Diaphragm plate 20 Cap scr.
8 Spring 21 Lock washer
9 Lower diaphragm case 22 Micro-valve
10 Stem 23 Bushing
11 Bleeder filter 24 O-ring
12 Bushing 25 O-ring
13 Set collar

42
Figure I-7.12C, INVALCO Switching Valve Assembly

43