HEMICAL NGINCERING FACTS AT YOUR FINGERTIPS Department Editor: Scott Jenkins precise monitoring ond conto of eee eee tomation ofboth discrete and continuous procesies. Measurement of vale position provides the doto required forthe use of fdvanced conto strategies ond predictive mmointonance algorthms More effecive monitoring of vale posi Yon hos been on ora n which consider able progress has been made in improving the pertormonce and reliability of contol voles. Mader elocical valo-postion indicators offer either mechanical or non contac switching The poston indicotors ‘re ically mounted either diracly on @ ‘lve actuator or work indirectly using a roncontact remote feedback device Mechanical switches ‘Most mechanicalswitch vale positioners [Figure, top le utlize some type of rotary potentiometer for converting linear to rotary Feedback. These widely used devices ore similar to variable resistors Rotory potentiometers have an arched coil cof wire, over which an arm, called @ wiper, slides. The wiper is tached fo the valve cam shah, and as it moves across the coil of wire, difering votlage outputs produced, The voltage output is proportional ta the ‘angle at which the wiper is oriented. ‘Mechanical switches include contact link- ‘ges thot are subject to Wear overtime. The ‘wear can eventually degrade performance. Non-contact proximity positioners Non-contact chology epproaches to valve positioning can provide accurate \alveposition data without the need forthe linkages or levers required by taditional systems, Avoiding mechanical contact inthe valve positioning system addresses some ofthe performance and cost challenges ‘associated with contol valves ineluding mechanicol wear, environmental hozords, human error and inaccurate readings, ‘Many non-contact proximity positioners {Figute, top right) incorporate control loop feedback mechanism bosed on an ‘analog PID (proportional inegrol derive fe] lori tot hos been updeted Yor digital device. The algorithm incorporates the ZieglerNichols (ZN) tuning procedure, { wellknown method for tuning automatic Controls. Tis @ two-step tuning approach that adjusts how agressively the valve con- troller reacts 1 errors between the process ‘oricble ond the desired setpoint Hallettect sensors ‘A number of non-contact proximity posto es re based on the solidstate Hall effec, ‘ond ore used to help improve monitoring ‘and control of production processes, The Hall lfec refers to potential diffe: ence, known as the Hall vollage, between ‘opposite sides of an electrical conductor through vhich an elacric current is lowing, The Holl offect is created shen @ magnetic eld ie plied perpendicular to the curent direction ‘A sensor using the Holl effect is @ wane dlucar that returns 6 vol ge output according 0 changer in the magnetic field, For valve postion Sensing, an integrated Holleffect sensor ond magnet assembly detect the presence, absence nd orientation of @ magnetic rigger. The fonsor is powered by @ constont current, ond develops o varying electrical potential thot is proportional ta the flux density of @ magnetic field applied perpendicular tothe xis ofthe senor. Hollofectproxim ily sensors used for vale posining offer Increased relly in exteme environmen These sensors eliminate cll mechonical contact Behraen the vole octuc- tor andthe Hanser Because there are no moving pars within the Hollefect sensor and mognet, the life expectancy is improved compared to 0 tradionalelecromechanieal switch Rood switches Some non-contact valve positioners ar bed on ved switches. A raed switch is an electrical swich hat is operated by an ‘plied magnetic fed, Reed switches have poi of electrical contacts on fertous matol ‘eed ino hermsialy sealed glass envo- lope. An applied magnetic field moves the reed, causing the contacs fo either touch for move apart. The contacts cn either be pen normally, closing when a magnetic fed is preset, or closed normaly, opening inthe presence of 0 mogreti field. Biv: cated reed switches con be used in applica tions where vlalow power or capacive discharge consideration or in alfect Benefits Significant benefits for noncontact valve positioners, include the following Greater flexibility — Non-contact postion utlizing Halletfect sensors provide Feedback on valve postion without link: ‘ages, levers or rotory of linear seals. This eee ere bbe mounied a considerable distance from the electronics enclosure, giving engineers increased flexibility and improved safety 4 ‘solid state reliability ~ Sofety integrity level {Sl raings ore higher with noncontact sensors ond low-power solenoids. Sils ore ‘© measure of safely system performance. Higher SIL numbers mean better sfety performance and higher confidence i the Hild deviee. lower costs — Non-contact valve postion ‘1s have o lower overall foal cos! of own- ‘csp than conventional devices, thanks to the precise positioning capobiliies thot can be customized by valve application. Also, the cost of ownership is lowered penetra diognosis for predictive maintenance Signatures. Increased versatiliy — Non-contact valve positioners are designed to be compatible wih most stondard industrial communica tions protocols, including HART, Foundation Fieldbus, AS!, Modbus, DeviceNet and Profibus. These devices can help engineers take advantage of he cost sovings and in- creased diagnostic copabiliies of nehworks, ‘long wit the advantages offered by improved postion sensors. Metin of ace ot You mpl a ec Strate al ela 3 ‘once in Valve Postion Monts, Hck oppecred Inthe Dacombsr 2007 uswe of Chemica) Engineer Ing. pp. 46-80,