Process Instrumentation & Control BTK3274

EXPERIMENT 4: CONTROL VALVE

OBJECTIVE
1. Understanding I/P and control valve principle and operation.
2. Compare signal trend for ATO & ATC control valve.

PROCEDURES:
Before starting the following experimental procedures, perform and review the “Start-up Check List
and Preliminary Exercises” and “Planning the Experiments” detailed in the earlier section for the
proper setup. Proceed with the experiment as follows:
1. Familiarize with the physical specifications and measuring principles of the Current-to
Pneumatic (I/P) converter for calibration check. Locate its “AIR SUPPLY” and “OUTPUT” ports.
Open its cover and locate its zero “-> 0 <-” and span “<-->” terminals. Locate its “+” and “-”
terminal block which has cable extensions labeled with “mA+” and “mA-”. Obtain the
specification by referring to the tag at the converter cover and record it into TABLE A.
Familiarize with the calibration terms used.
2. The I/P converter needs to be set up with the appropriate input and output calibration or test
equipment and proper connections.
3. Instrument Air Supply (IAS) for I/P converter
The I/P converter needs instrument air supply (IAS) to function. Connect the instrument air
supply using the flexible tubing to its supply “SUP” port of the I/P with 1.4 bar air supply (source)
from Model ICS911. Note that the same IAS shall be supplied for both I/P converter and air filter
regulator of the control valve.
4. Pressure Output (i.e. Pressure Output from I/P converter)
The I/P converter output is standard 3 to 15 psig signal. Decide the pressure output signal (in psi)
for the tested calibration range, to be read from the I/P converter. Two methods are provided
here:

Method 1: signal calibrator with pressure module.

• Locate the I/P converter output “0” port. Connect this “0” port to the “Pressure Port”
of the pressure module. Leave the “Reference Port” of the pressure module open to
atmosphere.
• Plug the pressure module (black cable) to the “pressure” slot (bottom) of the signal
calibrator.
• Make sure no leaks at all the tubing connection points.
• Switch on the signal calibrator. Make sure “PRESSURE psi” is selected at the upper display.
• Read the pressure output from the I/P converter from the signal calibrator.

Method 2 : pressure calibrated input I or II at Model ICS911

• Connect the I/P converter pressure output “0” port to the calibration input I or II at Model
ICS911. Make sure the selector switch position is corresponding to the calibration input
selected.
• Make sure no leaks at all the tubing connection points.

5. Current Source (i.e. Current Signal Input to I/P converter)

The source of the current (4-20mA) input shall be simulated from the signal calibrator. Switch on
the signal calibrator. Make sure “mA OUT” is selected at the lower display of the signal
calibrator. Connect the leads to its mA terminal and with I/P “mA+” and “mA-” terminals.
6. Perform a five-point calibration check on the I/P converter. Start the instrument calibration at a
0% calibration range at 4 mA. Once the desired input current is obtained, the input and output
signals are recorded into Table A.
7. Then, enter the input current (mA) using the keypad to the suggested calibration range as
shown in summary list of the recommended currents. Once the desired input current is
obtained, the input and output signals are recorded into Table A.
8. Repeat the above procedures for the next suggested currents. Below is a summary list of the
recommended currents.

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Process Instrumentation & Control BTK3274

Recommended current
No %range Use current source
Read current at calibrator (Ametek ASC300)
1 0 4.0 mA
2 25 8.0 mA
3 50 12.0 mA
4 75 16.0 mA
5 100 20.0 mA

9. Calculate % accuracy and % deviation. Identify any zero drift, span error, combined zero drift
and span error. If adjustment is needed to eliminate errors, use the zero “-> 0 <-” and span “<--
>” terminals of the I/P converter.
10. Repeat the above steps 6-9 for RUN II. Record down the readings in TABLE B.
11. The pressure output from the calibrated I/P converter can then be connected to the positioner
of the pneumatic control valve for five-point visual stroke check.

Air to Open (ATO) valve

Follow the following procedures if the control valve is Air-to-Open (ATO) type.
i. Start the visual check at a 0% calibration range (I/P) at 4 mA. Once the desired input
current is obtained, the input mA and control valve opening % (see at the control valve
opening indicator) are recorded into Table C. Note that at 4mA, the control valve
should indicate 0% open.
ii. Then, enter the input current (mA) using the keypad to the suggested calibration range
as shown in summary list of the recommended currents. Once the desired input current
is obtained, the input signal and control valve opening % are recorded into Table C.
iii. Repeat the above procedures for the next suggested currents as in step 8.
iv. If time permits, repeat for RUN II.

Air to Close (ATC) valve

If the control valve is Air-to-Close (ATC) type, visual stroke check as follows:
i. Start the visual check at a 0% calibration range (I/P) at 4 mA. Once the desired input
current is obtained, the input mA and control valve opening % (see at the control valve
opening indicator) are recorded into Table D. Note that at 4mA, the control valve
should indicate 100% open.
ii. Then, enter the input current (mA) using the keypad to the suggested calibration range
as shown in summary list of the recommended currents. Once the desired input current
is obtained, the input signal and control valve opening % are recorded into Table D.
iii. Repeat the above procedures for the next suggested currents as in step 8.
iv. If time permits, repeat for RUN II. Identify any zero drift, span error, combined zero drift
and span error and nonlinearity. If adjustment is needed to eliminate errors, use the zero
(at control valve feedback arm) and span (at positioner) screws.

12. After the Experiment,

• Disconnect the IAS from the I/P converter
• Disconnect the pressure output connection (at signal calibrator/pressure module or test
gauge) from the I/P converter
• Disconnect the cables from signal calibrator
• Keep all the tubings and cables.
13. SHUT-DOWN After all experiments are completed, switch OFF the main power supply and main
instrument air supply.

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Table A: Current-to-pneumatic (I/P) converter calibration check

Run I
Model number :
Serial number :
Maximum deviation :
Tag number :
A B C D E F G H
Input Output Measured Theoretical % Accuracy % Deviation Dev. limit Remarks
current current, output, psig output, psig (D-C)psig (C-D)psig Pass: if
x 100% x 100%
applied, mA D psig (15-3) psig Deviation
mA at % of %<± Dev.
calibration Limit
range Fail: if
otherwise
4 at 0% 3
8 at 25% 6
12 at 50% 9
16 at 75% 12
20 at 100% 15

Note
A: Current injected to the converter using a signal calibrator for 4 to 20 mA
8 mA-4 mA
Example: x 100%=25%
20 mA-4 mA
B: Read from the signal calibrator for current injected into I/P converter
C: Read from the signal calibrator or test gauge and the measured output signal is compared to the theoretical output
signal
D: Theoretical output signal. Example for 25% calibration range, theoretical output of the 3-15 psig signal is
[(15-3)x0.25]+3 psig = 6 psig
G: Deviation provided by the manufacturer’s calibration certificate, if any.

Table B: Current-to-pneumatic (I/P) converter calibration check

Run I
Model number :
Serial number :
Maximum deviation :
Tag number :
A B C D E F G H
Input Output Measured Theoretical % Accuracy % Deviation Dev. limit Remarks
current current, output, psig output, psig (D-C)psig (C-D)psig Pass: if
x 100% x 100%
applied, mA D psig (15-3) psig Deviation
mA at % of %<± Dev.
calibration Limit
range Fail: if
otherwise
4 at 0% 3
8 at 25% 6
12 at 50% 9
16 at 75% 12
20 at 100% 15

Note
A: Current injected to the converter using a signal calibrator for 4 to 20 mA
8 mA-4 mA
Example: x 100%=25%
20 mA-4 mA
B: Read from the signal calibrator for current injected into I/P converter
C: Read from the signal calibrator or test gauge and the measured output signal is compared to the theoretical output
signal
D: Theoretical output signal. Example for 25% calibration range, theoretical output of the 3-15 psig signal is
[(15-3)x0.25]+3 psig = 6 psig
G: Deviation provided by the manufacturer’s calibration certificate, if any.

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Table C: Control valve (ATO) visual check

Run I Run II
Model number :
Serial number :
Maximum deviation :
Tag number :
A B C D A B C D
Input Output Visual Theoretical Input current Output current, Visual Theoretical
current current, check on output applied, mA at mA check on output
applied, mA valve (valve % of calibration valve (valve
mA at % of opening, % opening),% range opening, opening),%
calibration %
range
4 at 0% 0 4 at 0% 0
8 at 25% 25 8 at 25% 25
12 at 50% 50 12 at 50% 50
16 at 75% 75 16 at 75% 75
20 at 100% 100 20 at 100% 100

Note
A: Current injected to the converter using a signal calibrator for 4 to 20 mA
8 mA-4 mA
Example: x 100%=25%
20 mA-4 mA
B: Read from the signal calibrator for current injected into I/P converter
C: Visual check at the control valve indicator

Table D: Control valve (ATC) visual check

Run I Run II
Model number :
Serial number :
Maximum deviation :
Tag number :
A B C D A B C D
Input Output Visual Theoretical Input current Output current, Visual Theoretical
current current, check on output applied, mA at mA check on output
applied, mA valve (valve % of calibration valve (valve
mA at % of opening, % opening),% range opening, opening),%
calibration %
range
4 at 0% 0 4 at 0% 0
8 at 25% 25 8 at 25% 25
12 at 50% 50 12 at 50% 50
16 at 75% 75 16 at 75% 75
20 at 100% 100 20 at 100% 100

Note
A: Current injected to the converter using a signal calibrator for 4 to 20 mA
8 mA-4 mA
Example: x 100%=25%
20 mA-4 mA
B: Read from the signal calibrator for current injected into I/P converter
C: Visual check at the control valve indicator