REF: IG/20-05/2004 DATE: 20/05/2004

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Introduction to VaIve Positioners
What is a VaIve Positioner?
Following are few descriptions about the Valve Positioners:
A Valve Positioner is the critical link between the controlling elements in a plant and the
final control element, the control valve.
The Valve Positioner compares the valve/actuator position to a desired input signal and
influences the valve/actuator so that its position corresponds with the desired input signal.
A Valve Positioner is a device used to increase or decrease the air pressure operating the
actuator until the valve stem reaches the position called for by the instrument controller.
Valve Positioners are often required to operate under difficult conditions such as high
vibration, extreme temperatures, corrosive environments, poor air quality, and general
abuse. Quite often, these products are expected to perform to exact requirements, and
remain maintenance free, under these rugged conditions.
Positioners are generally mounted on the side or top of the actuator. They are connected
mechanically to the valve stem so that stem position can be compared with the position
dictated by the controller.
T TE EC CH HN NI IC CA AL L B BU UL LL LE ET TI IN N
REF: IG/20-05/2004 DATE: 20/05/2004
INSTRUMENTATIONGUIDE.COM
129, Damji Shamji Industrial Estate, off Mahakali Caves Road,
Andheri {E), Mumbai - 400093, India.
Tel. No.: 91-022-56963030J91-022-26S7477S. Fax No.: 91-022-26S73613.
Email: info@instrumentationguide.com
When to Use VaIve Positioners?
Many reasons have been suggested for using Valve Positioners:-
N When friction must be overcome.
N When long transmission distances are encountered.
N When extreme or variable pressure can offset the valve plug.
All the above reasons make sense, but none of them includes any consideration for the
process that is to be controlled.
Adding positioner to a valve may cause oscillation in one control loop, while stabilizing
another. In fact, a loop containing a given controller, valve, piping, pump etc. may exhibit
oscillations when controlling flow if positioner is used, or when controlling level when
positioner is not used.
Every valve exhibits from 2 to 10 % hysterisis (unless equipped with positioner) because of
friction in the guides and packing. Whenever the direction of control signal is reversed, the
stem remains in its last position until the hysterisis band is exceeded. Widening the
proportional band will not dampen the oscillation, but only makes it slower. The limit cycle
will not appear if a proportional controller is used or if the process has no integral element.
Process that are prone to limit cycling in such characteristic way are liquid level, volume,
weight and gas pressure - all of which are integrals of flow. Whenever we intend to control
one of these processes with proportional plus reset controller, use a valve positioner. It will
avoid the limit cycle by closing a loop around the valve actuator.
Processes like flow or liquid pressure have no integrating element - hence they respond
much faster. In fact, the valve tends to be the slowest element in such loops. Also the
slowest element in a loop determines its dynamic gain and hence proportional band is
required for stability of such loops.
Adding a positioner to a valve greatly increases its speed of response and consequently its
dynamic gain. When a positioner is added to a flow loop the proportional band of its
controller may have to be widened by almost 5 fold to restore stability.
Hence, when a transmission line length poses a problem in a flow loop, use volume booster
or install the controller close to the valve.
For temperature control, a positioner will be helpful but not essential, depending on how
much hysterisis is in the valve itself.
REF: IG/20-05/2004 DATE: 20/05/2004
INSTRUMENTATIONGUIDE.COM
129, Damji Shamji Industrial Estate, off Mahakali Caves Road,
Andheri {E), Mumbai - 400093, India.
Tel. No.: 91-022-56963030J91-022-26S7477S. Fax No.: 91-022-26S73613.
Email: info@instrumentationguide.com
Many of the technology suppliers insist on valve without positioners (bench set)
and driving the valves directly from the controllers - a quite logical solution for
the dynamic stability of the process.
A Positioner is a type of air relay which is used between the controller output and
the valve diaphragm. The positioner acts to overcome hysteresis, packing box friction, and
valve plug unbalance due to pressure drop. It assures exact positioning of the valve stem in
accordance with the controller output.
Why to Use VaIve Positioners?
N Increase control system resolution: i.e. fine control.
N Minimize packing friction effects
N Negate flow-induced reactions to higher pressure drops.
N Increase speed of response.
N Overcome seating friction in rotary valves.
N Allow wide range of Process variation.
N Increase fast venting (unloading) capability.
N Permit use of piston actuators.
N Facilitate operation when the higher number in the bench-set range is greater
than 15 psig: i.e. 10-30 psig, 6-30 psig, etc.
N Reduce actuator sizing.
REF: IG/20-05/2004 DATE: 20/05/2004
INSTRUMENTATIONGUIDE.COM
129, Damji Shamji Industrial Estate, off Mahakali Caves Road,
Andheri {E), Mumbai - 400093, India.
Tel. No.: 91-022-56963030J91-022-26S7477S. Fax No.: 91-022-26S73613.
Email: info@instrumentationguide.com
Important considerations when selecting a VaIve Positioner are:
N Design
N Performance
N Reliability
N Durability
N Maintenance
Design
A simple, clean design are the most accepted positioner products on the market today.
Engineers and maintenance people have responded positively to the concept that in a
positioner, simpler is better.
Performance
How well does the unit do what it claims it will do? Such characteristics as gain, hysteresis,
repeatability, and linearity are key elements of the performance equation.
Performance should not only be evaluated with these engineering terms and numbers, but
with the real life world of actual plant operations.
ReIiabiIity
How well does the positioner meet the performance specifications, in the very difficult
environment that control valves, actuators, and positioners often find themselves?
Meeting the performance specifications, under difficult conditions, helps determine the
products reliability.
DurabiIity
How long does the positioner maintain its specifications under difficult environmental
conditions? The life expectancy of all industrial products is determined by the user.
Under the installed conditions, is the product durable enough to meet the user's
expectations?
Maintenance
There are no maintenance free industrial products that are installed on control valve
packages. Maintenance should be a function of frequency and simplicity.
Two key EIements are aIso considered:
Dynamic Loop Performance - Valve Positioner Issues
Flow Gain Vs Pressure Gain
REF: IG/20-05/2004 DATE: 20/05/2004
INSTRUMENTATIONGUIDE.COM
129, Damji Shamji Industrial Estate, off Mahakali Caves Road,
Andheri {E), Mumbai - 400093, India.
Tel. No.: 91-022-56963030J91-022-26S7477S. Fax No.: 91-022-26S73613.
Email: info@instrumentationguide.com
How Positioners Work?
Although there are many different types of positioners, the basic principles of operation are
similar for all of them.
PrincipIe of Operation:
The positioner is mechanically connected to the stem of the valve. This stem position
is compared with the position called for by the instrument controller, i.e. by the instrument
output air signal. A separate air supply is brought into the positioner for positioning the
valve at exactly the point called for by the controller.
This BuIIetin is provided by Mr. V.P. Raman, for more information, feedbacks & suggestions
regarding technicaI buIIetin, you can contact him at ramanvp@waaree.com
Yours truIy,
Indrajit Banerjee.
indrajitbanerjee@waaree.com
InstrumentationGuide.com,
129 Damji Shamji Industrial Complex,
Off Mahakali Caves Road,
Andheri {East), Mumbai - 400093
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