Page 1 54 · Page 1 of 54 2016 Muhammad Fuad Abd Halim Murdoch University 1/1/2016 Operability and Performance Analysis of Various Control Valves . ENG70 ENGINEERING HONOURS THESIS

Page 1 of 54

Page 1 of 54

2016

Muhammad Fuad Abd Halim

Murdoch University

1/1/2016

Operability and Performance Analysis of Various Control

Valves

ENG70 ENGINEERING HONOURS THESIS Fuad Halim

Page 2 OPERABILITY & PERFORMANCE ANALYSIS OF VARIOUS CONTROL VALVES

Abstract A control valve is a force worked gadget which alters the

liquid stream rate in a procedure control framework. It comprises of

a valve associated with an actuator component that is equipped for

changing the position of a stream controlling component in the

valve because of a sign from the controlling framework.

This thesis is about operability and performance analysis of

various control valves in Murdoch University. The hardware test

and the behaviour test have been done throughout the project. The

results are provided through the report exclusively.



DECLARATION

I declare that all parts of this report are the result of my own work except for the

quotation and references, the sources of which have been acknowledgement in the

bibliography and references.

------------------------

Muhammad Fuad Abd Halim

Student ID: 32157709



Acknowledgement

The completion of this thesis could not have been possible without the

participation and assistance of my supervisor Associate Professor Graeme

R. Cole and co-supervisor Dr. Linh Vu. Their contributions are sincerely

appreciated and gratefully acknowledged.

I would like to extend my thanks to my family who offered moral

support and advice continuously.



Table of Contents Abstract ................................................................................................................ 2 Acknowledgement .................................................................................................... 4 Terms and Abbreviations ............................................................................................ 7 1. Introduction ..................................................................................................... 8

Objective ................................................................................................................9 Purpose ..................................................................................................................9

2. Literature Review ............................................................................................. 10 Control Valve.......................................................................................................... 10 Control Valve Types .................................................................................................. 10 Control valves need to be tested .................................................................................... 11 Baumann 24000S with electric actuator ........................................................................... 12 Baumann 51000 High-Pressure Low-Flow Control Valve ....................................................... 13 Baumann 24000S with Fisher 3660 Positioner ................................................................... 14 Badger Meter Research Control Valve ............................................................................. 15 Software for Simulation and Log the Data ......................................................................... 16 Front Panel ............................................................................................................ 16 Block Diagram ........................................................................................................ 18 Device for control valve configuration ............................................................................. 19

3.Technical Approach ............................................................................................... 20 Methodology .......................................................................................................... 21 Control Valve Leak Test testing ..................................................................................... 22 Control Valve Validation and Calibration .......................................................................... 24

4. Results ............................................................................................................. 32 Control Valve Validation and Calibration Test Results ........................................................... 32 Hysteresis Results .................................................................................................... 34 Dead Band Results ................................................................................................... 38 Results summary ..................................................................................................... 42 Summary of Calibration Results .................................................................................... 42 Summary of Behaviour Testing Results ............................................................................ 43

5. Conclusion ..................................................................................................... 44 6.Future works ...................................................................................................... 45

Perform calibration .................................................................................................. 45 Leak test ............................................................................................................... 45 Pressure drop in the ICE laboratory................................................................................ 45

7.References ......................................................................................................... 46 Bibliography .......................................................................................................... 47

8.Appendices ......................................................................................................... 48

Table 1 : Types of Control Valve ........................................................................... 11 Table 2 : Baumann 24000S with Electric Actuator Terminals ..................................... 12 Table 3 : ANSI/FCI 70-2-1976 Classification (lifes, lifes and profile) ............................... 23 Table 4: Calibration table ..................................................................................... 25 Table 5 : Summary of Calibration Results ............................................................... 42 Table 6 : Summary of Behaviour Testing Results ..................................................... 43 Table 7: Flow rate Data from Labview and Flow meter (Magnetic Flow Meter) ............. 53 Table 8 : Hysteresis data 1 ................................................................................... 53 Table 9 : Hysteresis data 2 ................................................................................... 54 Table 10 : Hysteresis data 3 ................................................................................. 54 Table 11 : Hysteresis data 4 ................................................................................. 54



Figure 1 : Baumann 24000S with electric actuator................................................... 12 Figure 2 : Baumann 51000 High-Pressure Low-Flow Control Valve............................. 13 Figure 3 : Baumann 24000S with Fisher 3660 Positioner .......................................... 14 Figure 4 : Badger Meter Research Control Valve ...................................................... 15 Figure 5 : LabVIEW 2014 ..................................................................................... 16 Figure 6 : LabVIEW front panel for control valve step change and monitor the real- time

level or pressure in the tank and graphs ................................................................ 17 Figure 7 : LabVIEW block diagram for the program and log the data to Microsoft Excel

file .................................................................................................................... 18 Figure 8 : Project Block Diagram ........................................................................... 21 Figure 9: Calibration Setup ................................................................................... 24 Figure 10 : Hysteresis characteristic graph (Process Industry Forum 2016) ...................... 27 Figure 11 : Water System Setup ........................................................................... 28 Figure 12 : Air System Setup ................................................................................ 29 Figure 13: Validation Graph for Baumann 24000S with electric actuator ..................... 32 Figure 14: Validation Graph Baumann 5100 Control Valve #01 ................................. 33 Figure 15: Validation Graph Baumann 24000S Control Valve with Positioner ............... 33 Figure 16 : Baumann 24000S with Electric Actuator (Water System) ......................... 35 Figure 17 : Hysteresis for Baumann 24000s with Fisher Positioner (Water System) ..... 35 Figure 18 : Hysteresis for Badger Meter Control Valve (Water System) ...................... 36 Figure 19 : Hysteresis for Baumann 24000s with Fisher Positioner (Air System) .......... 36 Figure 20 : Hysteresis for Badger Meter Control Valve (Air System) ........................... 37 Figure 21 : Badger Meter Research Control Valve Dead Band Test ( Air System) ......... 38 Figure 22 : Baumann 24000S with 3660 Positioner Dead Band Test ( Air System) ....... 39 Figure 23 : Baumann 24000S with 3660 Positioner Dead Band Test (Water System) ... 39 Figure 24: System Valve-Flow Characteristics and Dead Band Region ........................ 41

Equation 1 : Liquid flow equation (McMillan and Considine 1999) .............................. 30 Equation 2: Linear equation for Badger Research Control Valve ................................. 41



Terms and Abbreviations

LabVIEW - (Laboratory Virtual Instrumentation Engineering

Workbench)

Cv – Valve coefficient

ANSI – American National Standards Institute

API - Application Programming Interface

I/O - Input/Output

ICE – Instrumentation & Control Engineering

HART – Highway Addressable Remote Transducer Protocol

EXCEL – Microsoft Excel

MATLAB - Matrix Laboratory



1. Introduction One of the most critical instruments that has been utilized in the

process control industry is control valves. The purpose of the control

valve is to control four main components of the process which are

flow, pressure, temperature and level respectively. Upon receiving

signals from the controller that compares a “setpoint” to a “process

variable”, the control valve will automatically reacts to these

signals. As a matter of fact, the control valve is also known as “Final

Control Element” whereby its task is to guarantee the quality and

the quantity of the end product in the classic control loop of the

control system. Subsequently, valve’s actuator, valve’s positioner

and valve’s body are the three fundamental parts that exist in the

control valve.

Furthermore, the control valves act as a device that persistently

with orifice in a fluid flow line. Change is the rate of flow variable

value which is caused by the variation of the control valve.

Necessarily, the control valve accommodates an adequate amount

of power in translating the controller’s output to the process in the

condition of either two positions (on-off) or proportional (throttling).

A successful control valve installation requires selection and sizing

which the valve must be affirmed in order to acknowledge when to

exceed the line of specification as well as the appropriate valve to

be chosen for the processes. It is well understood that the

performance of the control valve installation is highly affected by

the type of the valve and the size of the valve itself. Therefore, the

control valve should be sized to match the flow requirement at any

conceivable conditions.

Under the circumstance of fulfilling the process requirement, the

type of the control valve needs to be selected carefully based on the

condition of the process. Different types of control valves carry



distinctive specialties. For example, a motor operating valve is use

for a high pressure. All in all, in the process control industry, the

selection of the control valve which involves common valve

attributes such as linear, equal percentage and quick opening plays

a crucial effect as wrong choices may bring harm to the plant.

Objective

The aim of this project is to test and check the functionality as well

as the behaviour of the control valves on the process. All the control

valves have been calibrated by the manufacturer, however to

ensure the control valves have been calibrated correctly and the

performance of the control valves are tallied with the manufacturer

specifications.

The usage and the functionality of the new control valves will be

analysed and will be compared with the existing control valves in

the Instrumentation and Control Laboratory. The comparison of the

performance, functionality and validation of the calibration of the

control valves between new and old control valves will be done

throughout the project.

The proposed goals of the project expected to be achieved are:

o The importance of the control valve calibration

o Hardware will affect the process

o Prove of theoretical feasibility with the actual

o Comparison of the behaviour stand-alone and control valve in

control system

Purpose Operability and Performance Analysis of Various Control Valves has

been assigned to study the operability and performance of the

control valves in Murdoch University.



2. Literature Review Control Valve

The control valve is controlled of a valve with an externally powered

actuator. The control valve is designed specifically for reliable

continuous throttling with minimum backlash and packing friction.

The control valve is involved with the disposition of energy in a

process. It dispenses energy from the source, dissipated energy

that exists within the system, or distributes energy in the system in

one way or another.

The chemical and petroleum industries have many applications

requiring control of gases, liquids, or vapours processes. Many

process operations require regulation of such quantities as density

and composition, but by far the most important control parameter is

flow rate. A regulation of flow rate emerges as the regulatory

parameters for reaction rate, temperature, composition, or a host of

other fluid properties. For this purposes the control valve is using as

the process control element.

Control Valve Types

There are numerous sorts of control valve in the business relying

upon the development of the valve and they will characterized in

various names. Be that as it may, just two general sorts in light of

how the valve conclusion part is moved; which is by straight

movement or rotational movement. Clients of the control valve

need to choose the sort of movement of the valve relying upon the

procedure the plant.

There are a few sorts of control valve that can use to execute the

procedure. The valves most generally utilized as a part of

procedures are ball valves, butterfly valves, globe valves, and fitting



valves. The control valves in the ICE laboratory are ball valve.

Table 1 demonstrates the control valve sorts.

Valve Type Application Other information

Ball Flow is on or off Easy to clean

Butterfly Good flow control at high capacities Economical

Globe Good flow control Difficult to clean

Plug Extreme on/off situations More rugged, costly than ball valve

Table 1 : Types of Control Valve

Control valves need to be tested

There are four types of control valves, out of which two have been

installed the Instrumentation Control Engineering (ICE) lab in

Physical Science building, the latter two types will be installed in the

(ICE) laboratory as well because their performance testing is part of

the project. The new type of control valves need to be installed in

the ICE lab are Baumann 2400s with the electric actuator, Baumann

Fisher 3660 Positioner and Baumann 5100 High-Pressure Low-Flow

control valve. An overview about of each type of the control valves

in term of functionality, behaviour and performance.



Baumann 24000S with electric actuator

A control valve with an electric is actuator also known as a motor

operated valve. Normally this type of control valve is a slow-

response valve. The application of the electric control valve is

whenever frequent operation is required.

Figure 1 : Baumann 24000S with electric actuator

Supply voltage for Baumann 24000S with electric actuator either

can use 24VDC or 24VAC. For communication signal this valve use

4-20mA and 2-10V as a feedback signal. This control valve does not

need instrument air as the actuator electronically shifts the valve

stem. Table 2 shows the summary of the electrical wiring for the

electric actuator.

Terminal No. Purpose

1 24VDC negative (-ve)

2 24VDC positive (+ve)

3 4-20mA signal communication

5 4-20mA signal communication Table 2 : Baumann 24000S with Electric Actuator Terminals



Baumann 51000 High-Pressure Low-Flow Control Valve

The Baumann 51000 control valve is used for a process that

requires a high pressure and low flow. The control valve is ideal for

the control purpose in the ICE lab. The physical size of this valve is

small and weight of the valve is light, which is good for laboratories

because it is easy to carry and suit to the limited space in the

laboratories. The actuator of the control valve can be chosen by the

user either in air-to-open mode or air-to-close mode because the

actuator has a multi-spring with low friction. There are two types of

Baumann 51000 in the control labs, one with Cv (flow coefficient) of

1.5 and one with Cv of 0.45. This control valve can allow accurate

control of very low flow. Both of them have the same body pressure

rating of 3000 psi.

Figure 2 : Baumann 51000 High-Pressure Low-Flow Control Valve



Baumann 24000S with Fisher 3660 Positioner

The Baumann 24000S with Fisher 3660 Positioner is a special

control valve because this is the single acting pneumatic valve

positioner. This control valve have two main parts. The valve body

manufactured by Baumann and the pneumatic positioner

manufactured by Fisher. The positioner of this control valve has its

own controller to control the arm of the positioner to eliminate the

dead band. This control valve has pressure indicator to check the

pressure output.

Figure 3 : Baumann 24000S with Fisher 3660 Positioner



Badger Meter Research Control Valve

Badger Meter Research Control Valve is the existing control valve in

the ICE laboratory. This control valve is low flow control type which

is suitable for critical control of liquid and gas. The actuator of this

control valve use air to activate and deactivate. There are two types

of this valve in the ICE laboratory; one is used for the water system

and one is for the air system. The difference of these two control

valves is the valve coefficient (Cv). Figure 4 illustrates the Badger

Meter Research Control Valve in the ICE laboratory.

Figure 4 : Badger Meter Research Control Valve



Software for Simulation and Log the Data

LabVIEW is the software that use graphical programming language,

which communicates with the hardware as data acquisition,

instrument control and industrial automation. This software has

been produced by the company named National Instruments. The

software can be used to monitor and control the process. Data can

be logged into EXCEL file by using one of the features in LabVIEW.

In this project, the simulations and the data of the project will be

analysed and discussed.

Figure 5 : LabVIEW 2014

Front Panel The front panel of the LabVIEW is shown in Figure 6, the front panel

is the human interface for the project. To run the program, the run

button on the top toolbar of the LabVIEW is switched ON. The

second step is to push the data logging button, which is to log data

to a file, which can be analysed by using EXCEL. To run the water

system, toggle switch named digital output to be toggled to the top

to switch on the water pump. The indicators set in the program to

illustrate if any trigger occurs in the system. On the left hand side is



the tank of the system which shows the water level or the air

pressure. To varies the step change of the manipulated variable

which the control valve, the slider has been used. The control valve

step has been named for the slide. Users can use the digital input at

the bottom of the slider instead of using the slider. It can help users

to give the exact values of step to the control valve. This is very

helpful to do experiment for dead band test where small step

change needed for that experiment. The waveform chart is

provided for user to monitor the graph of the manipulated variable

and the process variable.

Figure 6 : LabVIEW front panel for control valve step change and monitor the real- time level or pressure in the tank and graphs



Block Diagram

Figure 7 illustrates the block diagram of the program which has

been used in the front panel. In this block diagram, the wiring of

each component has been wired to the terminals. This section is

the back panel of the program. All the input and output of the

hardware will be assigned here such as analog input, analog input,

digital input and digital output.

Figure 7 : LabVIEW block diagram for the program and log the data to Microsoft Excel file



Device for control valve configuration

Multi calibrator Fluke 744 Documenting Process Calibrator is

combinational device that can calibrate temperature, pressure,

voltage, current, resistance and frequency. (Communications 2016)

This Fluke 744 can simulate and measure volts, mA, thermocouples,

RTDs, frequency and ohms. HART communication is a package of

Fluke 744 which has a role of sequencing of communication which is

suitable for control valve calibration. This device has been used

throughout the project to simulate the current to the control valves.



3.Technical Approach

To achieve the project objectives, this project needs to involve with the following stages:

Hardware testing:

o Leak test o Validation and calibration

Behaviour testing:

o Hysteresis o Valve sizing

o Dead band o Dead time

Test the valve with the process: o Introduce the control valve to LabVIEW and log the data

The project will begin with hardware testing, whereby all the control

valves need to go through a leak test. Leak test is very important

for the control valve to check the seal that has been installed to the

valve. On the other hand, leak test also can check the flow through

the valve. After leak test is done, all of the control valves need to

be validated and if they are not met specification, the control valves

will require calibration. For the behaviour testing, the sizing of the

valve will be studied to ensure that the control valve is suitable for

the process. The hysteresis, dead band and dead time will be

investigated to evaluate the valve’s behaviour and characteristic.

The last part is to introduce the control valve into the control

system. At this stage, the behaviour and the characteristics of the

valve will be observed and analysed. The comparison of behaviour

between stand-alone control valve and control valve in controlled

system will be considered. The modelling of the control valve will

also be developed in LABVIEW, MATLAB and Microsoft Excel. This

will be included in the documentation of the control valve testing.



Figure 8 : Project Block Diagram

FEASIBILITY STUDY

HARDWARE TESTING

BEHAVIOUR TESTING

ANALYSIS AND DOCUMENTATION



Methodology

Control Valve Leak Test testing

The Control Valve Leak Test is a test to check the integrity of the

valve seals (i.e. stem packing, bonnet, and other seal on the valve

body). In this test, if the valve flow can pass through from the inlet

to the outlet of the valve body, the control valve requires corrective

maintenance where the control needs to be overhaul.

The standard that used for the seat leakage is ANSI/FCI 70-2-1976

due to the material and pressure for the test. There are six different

seat leakage classifications. The most commonly classifications used

are CLASS IV and CLASS VI. (lifes, lifes and profile) Metal to metal

is classified under CLASS VI where the leakage is come from a valve

with metal plug and metal seat. The soft seat is classified as CLASS

VI where either the plug or seat or both are made from the

composition material as Teflon. (lifes, lifes and profile) More details

about classification are shown in Table 3. (lifes, lifes and profile)



Leakage Class

Designation

Maximum Leakage

Allowable Test

Medium Test Pressures Testing Procedures Required for Establishing

Rating

i *** *** *** No test required provided user and supplier

so agree

ii

0.5 % of rated

capacity

Air to water at 50

- 125 degree

Fahrenheit (10 - 52 degree Celsius)

45 - 60 psig or max operating

differential whichever is lower

Pressure applied to valve inlet, with outlet open to atmosphere or connected to a low

head loss measuring device, full normal closing thrust provided by actuator

iii

0.1 % of rated

capacity As above As above As above

iv

0.01 % of rated

capacity As above As above As above

v

0.0005 ml per minute

of water per inch of port

diameter per psi

differential

Water at 50 - 125 degree

Fahrenheit ( 10 - 25 degree Celsius)

Max service pressure drop

across valve plug, not to exceed ANSI body rating. ( 100 psi pressure drop

minimum )

Pressure applied to valve inlet after filling entire body cavity and connected piping with water and stroking valve plug closed. Use net specified max actuator thrust, but no more, even if available during test. Allow time for

leakage flow to stabilizer

vi

Not to exceed

amounts shown in following

table based on port

diameter

Air to Nitrogen at

50 - 125 degree

Fahrenheit ( 10 - 52 degree

Celsius )

50 psig or max rated differential pressure across

valve plug, whichever is lower.

Actuator should be adjusted to operating conditions specified with full normal closing thrust applied to valve plug seat. Allow time for leakage flow to stabilize and use suitable

measuring device Table 3 : ANSI/FCI 70-2-1976 Classification (lifes, lifes and profile)

This test requires high pressure hydrostatic pump and this test will

involve with high pressure. This cannot be done in this project but

the procedure for this test has been presented in Appendix B.



Control Valve Validation and Calibration

The control valve calibration is the testing to check the control valve

signal tally with the unit under the test instrument. This test

basically is to ensure the device signal giving the same

measurements as similar as test instrument. The control valve

calibration should follow some steps as shown in the procedure

section.

Every control valve has its own signal communication such as 2-

10v, 3-15psi and 4-20mA. The most common is 4-20mA as the

signal communication. In order to achieve this test, some specific

equipment needed.

Figure 9: Calibration Setup



Below are the steps to do for validation and calibration of a control valve:

Connect instrument air supply to the actuator of the control valve Connect the signal communication wire to the I/P converter

Procedure

The multi calibrator Fluke 744 Documenting Process Calibrator is used for

the valve calibration.

Method of calibration

First inject a pressure of 3psi to the control valve. The reading valve need to be taken. If the reading is 25% the valve is accurate. The zero and

spend technique need to be used if the reading valve is not tally 25%. The steps need to be repeated for 5 check point shows in Table 4.

When current (mA) Valve open

4 mA 0%

8 mA 25%

12 mA 50%

16 mA 75%

20 mA 100% Table 4: Calibration table

Tool required

Multi calibrator Fluke 744 Documenting Process Calibrator

Test Pen Screw Driver

Specifications

Analog valve control with fast control behaviour Inputs 4 to 20 mA, 0 to 20 mA or 0 to 10 V

Easy local mechanical configuration Mechanical adaptations by setting screws

Independent adjustment of zero and span Independent adjustment of gain and damping

Mounting to all linear and rotary actuators



Positioner Calibration

Set the valve position to the desired 4 mA equivalent to 0% This can be achieved by:

From remote, at the Operator Console, open up the respective valve detail window. Give an output value of 0%.

From local, connect a mA injector to the I/P converter and simulate a value of 4 mA.

Check the valve position and make sure it is at 0% opening.

Otherwise, adjust the 4 mA output with the trimpot labeled BIAS. Set the valve position to 20 mA equivalent to 100%.

Ensure that the actual valve position is at 100%. Else, adjust the 20mA output with the trim pot labelled SPAN.

Verify the zero position. Ensure that the zero position does not changed. Otherwise re-adjust.



Hysteresis

Hysteresis is a nonlinearity phenomenon that can affect the process

control. Hysteresis of the control valve can be study by upstroke

and down-stroke the control valve. (Process Industry Forum 2016)

The difference between the “valve opening” and “valve closing” at

any output signal such as flow rate, level or pressure. The

difference happens because of the high static friction of the valve.

Figure 10 shows the position of the control valve and the output

signal of flow rate. The red line is the “valve opening” and the blue

line is the “valve closing”. The “valve opening” and “valve closing”

are not being able to return at their original shape. (2016).

Figure 10 : Hysteresis characteristic graph (Process Industry Forum 2016)



Figures 11 and 12 shown the installation of the equipment to

perform hysteresis, valve sizing, dead band and dead time in the

ICE laboratory. Figure 11 shows the setup for the water and Figure

12 shows the setup for the air system.

V-2

E-5

P-1

F-1

Water supply tank

E-1

Displayed Text Description

E-5 Water Supply Tank

E-1 Water Tank

F-1 Magnectic Flow Meter

P-1 Water pump

V-2 Control Valve

Instruments List

Figure 11 : Water System Setup



V-1

E-3I-2

P-1

Displayed Text Description

E-2 Air Suply

E-3 Air Tank

I-2 Flow Meter

P-1 Pressure Sensor

V-1 Control Valve

Instruments List

E-2

Figure 12 : Air System Setup

To perform the hysteresis testing, the control valve needs to step

up from 0% to 100% constantly and also need to step down from

100% to 0% constantly as well while the steady state of the flow

rate need to be recorded. To get a good result of the hysteresis, the

steady state values of the of flow rate been recorded by using

LabVIEW and EXCEL. The flow meter values at steady state also

been captured manually to compared with the flow rate that been

logged by using LabVIEW. The results of the hysteresis will be

discussed in the hysteresis results section.



Control Valve sizing

Control valve sizing is related to the flow coefficient (Cv) of the

control valve. It is commonly used in the industry to select correct

valve size as a function of pipe size. (McMillan and Considine 1999)

The knowledge of the flow and process condition are the most

important to select the correct valve size. (McMillan and Considine

1999) Furthermore, the function and style information are also

needed. Valve’s sizing is based on theoretical and empirical data

combination.

The following equation has been used to perform valve sizing by

liquid flow equation.

Equation 1 : Liquid flow equation (McMillan and Considine 1999)

where,

Q = Flow rate(McMillan and Considine 1999)

Cv= Valve sizing coefficient, determined by testing(McMillan

and Considine 1999)

P1 = Upstream pressure(McMillan and Considine 1999)

P2 = Downstream pressure (McMillan and Considine 1999)

G = Liquid specific gravity (McMillan and Considine 1999)

In this project the flow coefficient was taken from the

manufacturer’s data sheets of the control valve. The flow coefficient

also written on the control valve’s label. The flow coefficient shows

the maximum value of flow that can be handle of the valve.



Dead Band

Dead band is a crucial factor for process variability and the

performance of the control valve. Dead band is a situation whereby

the position of the valve has been changed in both direction but it

does not affect the process variable. The failure to produce a

change in process variable will cause a bad process control. This

problem occurs due to backlash and friction from the mechanical

movement of the valve. One of the criteria that need to be

measured in order to obtain an excellent performance and accuracy

is to overcome the dead band issue. This is because dead band

could influence the performance and accuracy of the control valve.

By using LabVIEW, dead band for the control valve can be tested by

giving small changes of the manipulated variable.

Dead time

Dead time is the time when the control valve response due to the

step change. In the process control, this phenomenon known as

process time delay. It is the same phenomenon but in the control

valve it called dead time.



4. Results

Control Valve Validation and Calibration Test Results

Each control valves have been done Control Valve Validation and

Calibration Test has been done to all control valves. All of them

have passed the validation test, so calibration has not been

required. The results show the linear lines in Figures 11, 12 and 13

which mean the control valves are linear valves.

In this section, all the undertakings involved for this project will be

briefly explained. The undertaking task is Hardware Testing which

includes control valve leak test testing and control valve validation

and calibration.

Figure 13: Validation Graph for Baumann 24000S with electric actuator



Figure 14: Validation Graph Baumann 5100 Control Valve #01

Figure 15: Validation Graph Baumann 24000S Control Valve with Positioner



Hysteresis Results

The hysteresis testing has been done to all the control valves in ICE

laboratory. The results have been logged in LabVIEW and plotted by

using EXCEL. For the water system, three hysteresis results of

control valves and for the air system, the two hysteresis results will

be discussed in this section.

Figures 16 and 17 show the minimum difference of up stroke and

down stroke. The Baumann 24000S with an electric actuator control

valve shows less difference in hysteresis because this control used

electric motor to step up and step down. This travel position and the

flow rate of the opening and closing is almost the same. The

hysteresis graph for Baumann 24000S with positioner also shows

that not much different hysteresis of valve opening and valve

closing. This control valve with the positioner can eliminates the

hysteresis of the valve. The positioner of the control valve will

follow the setpoint and the air pressure will adjust the stem of the

valve. The graph for Badger Meter Research control valve in Figure

18 shows that the gap of hysteresis was quite obvious. This is

because of the friction happen to the valve due to “wear and tear”.

For the air system, the hysteresis graph of Baumann 24000S with

3660 positioner in Figure 19 shows there is no difference in valve

opening and valve closing. The response of valve to the step change

follows exactly the same as the setpoint. The positioner works

successfully without any error. Figure 20 shows the hysteresis of

the Badger Meter Research control valve for the air system. The

hysteresis of this control valve can obviously be observed. This

happen because of the age of the valve. This valve requires service

and maintenance.



Figure 16 : Baumann 24000S with Electric Actuator (Water System)

Figure 17 : Hysteresis for Baumann 24000s with Fisher Positioner (Water System)



Figure 18 : Hysteresis for Badger Meter Control Valve (Water System)

Figure 19 : Hysteresis for Baumann 24000s with Fisher Positioner (Air System)



Figure 20 : Hysteresis for Badger Meter Control Valve (Air System)



Dead Band Results

Dead band can be overcome by the general procedure controller.

This is not perfect as a huge blunder between the sought stream

rate and the deliberate stream rate is required for the controller to

bring about a change in the valve. The positioner does not require a

distinction in the coveted stream and the deliberate stream to be

influenced for remedial activity to happen. The positioner will

modify if there is a blunder between the sought stem position and

the deliberate stem position before the stream is influenced.

From Figures 19 and 20, the dead band of the valve can be

observed. As it can be seen, there is no change in flowrate despite

the steps change in valve position.

Figure 21 : Badger Meter Research Control Valve Dead Band Test ( Air System)



Figure 22 : Baumann 24000S with 3660 Positioner Dead Band Test ( Air System)

Figure 23 : Baumann 24000S with 3660 Positioner Dead Band Test (Water System)

Baumann 24000S with 3660 Positioner Dead Band



Valve calibration in ICE lab

Concerning valve familiarization and calibration, the aim was to

determine salient valve characteristics that can significantly affect

the output, or at least, allow for the design of more efficient control

methods that take into account these characteristics. Among others,

two of the most important valve characteristics are: valve

‘Deadband’ and valve-flow behaviour.

‘Deadband’, as its name implies, refers to the non-operating range

of a given element. Many, if not all, process elements have within

them some deadband region. However, most of this ranges are too

little to be of any significant influence to the overall system. For

this particular element, it is pertinent that discover its operating

ranges with respect to the input flow rate so that, where possible,

the deadband region can be avoided.

As previously mentioned, another salient valve property is its

relationship to flow rate and how ‘ideal’ this relationship seems.

There are three main categorization of valve-flow relationship and

each of these categories holds some form of advantage and

disadvantage over the other.

Figure 22, the flow-valve characteristic test has been performed to

analyse the flow specification of the control valve. The first step is

to open the valve through five stages until it is fully opened.

Meanwhile, the flowrate is recorded in Excel spreadsheet. By using

excel inbuilt trendline feature, the linear equation of the valve has

been developed as below.



Figure 24: System Valve-Flow Characteristics and Dead Band Region

The derived equation, with a correlation of 99.69%, is given below:

Equation 2: Linear equation for Badger Research Control Valve

Surmising form the image above, the conclusion that the chosen

valve has a dead band region approximately around 0-15% valve

opening and can safely categorize the valve-flow relationship under

the quick-opening type. This implies that:

The dead band region is redundant in terms of operating positions.

As a quick opening valve, the dead band region is a more significant detriment to the overall valve efficiency as this region could have

been capable of more sensitive control action since its gradient would have been less.

A little change in the valve positions would result in a relatively

significant change in the flow rate.



Results summary

Summary of Calibration Results

Table 5 : Summary of Calibration Results



Summary of Behaviour Testing Results

16

Table 6 : Summary of Behaviour Testing Results



5. Conclusion

This project commences to study the operability and to analyse the

performance the various control valves in the ICE laboratory. There

are two main test that have been done throughout the project

which are hardware testing and behaviour testing.

The hardware testing has been done successfully for new control

valves due to manufacturer calibration. The existing control valves

in the ICE laboratory been calibrated but still require service and

maintenance.

The hysteresis, dead band and dead time been tested to the control

valves. Two new types of control valve have less hysteresis and

dead band, because one of them using a motor to activate the valve

and another used positioner to eliminate the dead band. The new

Baumann 24000S with positioner is very suitable for experiment in

the ICE laboratory because this valve have a good performance.



6.Future works

In this section, the future works will be recommended in order to

improve the control valve experiment in the ICE laboratory. Future

work that should be done are as per below:

Perform calibration

Most of the instruments in the ICE laboratory required calibration

due the validation. This will help to give a good result for the

experiment for future student to study about the performance and

operability analysis of the control valves. The recommendation

period for the calibration is not more than six months due to

operability of the instruments every semester.

Leak test

Perform leak test for existing control valves in the ICE laboratory.

By performing leak test, the control valve can be observed either

required fully overhaul or any specific maintenance. This can help

student to troubleshoot the problem and give student exposure with

hands on experience.

Pressure drop in the ICE laboratory

The air supply in ICE laboratory sometimes have pressure drop

phenomenon while the experiment. This problem occurred because

of the air supply in the ICE laboratory been supplied with same

compressor, if many users use the air supply the pressure will drop

and will affect the experiment. To solve this problem, a new control

system needs to introduce at the compressor side to maintain the

air pressure.



7.References

1. Instrumentation.co.za,. 2015. 'Factors Affecting Control Valve Performance -

Part 4: Valve Type And Characterisation - February 2003 - Automation &

Control Solutions - SA Instrumentation & Control'.(Accessed August 2015)

http://www.instrumentation.co.za/article.aspx?pklArticleID=2265&pklIssueID=198&sessio

n-id=be3e2e7ed0fb496734e1f5b3be2e9d0e. 2. Fisher Controls International LLC.,. Control Valve Handbook. Singapore:

EMERSON Process Management, 2003. Print.

3. Google Books,. 'Instrument Engineers' Handbook, Fourth Edition, Volume

Two'. N.p., 2015. Web. 12 Aug. 2015.

4. Liptak, Bela G. Instrument Engineers' Handbook. Boca Raton, FL: CRC Press,

2006. Print.

5. Driskell, Les. Control Valve Sizing. Research Triangle Park, N.C.: Instrument

Society of America, 1982. Print.

6. Skousen, Philip L. Valve Handbook. New York: McGraw-Hill, 1998. Print.

7. lifes, Ratna, Ratna lifes, and View profile. 'HOW To Repair Your Self: Control

Valve Calibration'. Beyrepair.blogspot.com.au. N.p., 2010. Web. 18 Sept.

2015.(Accessed September2015)

http://beyrepair.blogspot.com.au/2009/11/control-valve-calibration.html

8. Maintenanceresources.com,. 'Cashco Seat Leakage'. N.p., 2015. Web. 18

Sept. 2015.( Accessed September2015)

http://www.maintenanceresources.com/referencelibrary/controlvalves/cashco

seatleakage.htm

9. Communications, Fluke. 2016. "Fluke 744 Documenting Process Calibrator

With HART Communications | Multifunction Calibrators | Instrumart".

Instrumart.Com. (Accessed January 2016)

https://www.instrumart.com/products/30264/fluke-744-documenting-

process-calibrator-with-hart-communications.

10. Process Industry Forum,. 2016. "Valve Terminology: Hysteresis, Deadband &

Linearity".

http://www.processindustryforum.com/article/valve-terminology-basic-understanding-key-

concepts. (Process Industry Forum 2016)

11. Emerson process,. 2016. "Instruction Manual D101402X012 Fisher 3660 And

3661 Positioners". (Emerson process 2016)

http://www.documentation.emersonprocess.com/groups/public/documents/in

struction_manuals/d101402x012.pdf

12. Process/industrial instruments and controls handbook

McMillan, Gregory K, and Douglas M Considine. 1999. Process/Industrial

Instruments And Controls Handbook. New York: McGraw Hill. In-

text: (McMillan and Considine 1999)

http://www.instrumentation.co.za/article.aspx?pklArticleID=2265&pklIssueID=198&session-id=be3e2e7ed0fb496734e1f5b3be2e9d0e

http://www.instrumentation.co.za/article.aspx?pklArticleID=2265&pklIssueID=198&session-id=be3e2e7ed0fb496734e1f5b3be2e9d0e

http://beyrepair.blogspot.com.au/2009/11/control-valve-calibration.html

http://www.maintenanceresources.com/referencelibrary/controlvalves/cashcoseatleakage.htm

http://www.maintenanceresources.com/referencelibrary/controlvalves/cashcoseatleakage.htm

https://www.instrumart.com/products/30264/fluke-744-documenting-process-calibrator-with-hart-communications

https://www.instrumart.com/products/30264/fluke-744-documenting-process-calibrator-with-hart-communications

http://www.processindustryforum.com/article/valve-terminology-basic-understanding-key-concepts

http://www.processindustryforum.com/article/valve-terminology-basic-understanding-key-concepts

http://www.documentation.emersonprocess.com/groups/public/documents/instruction_manuals/d101402x012.pdf

http://www.documentation.emersonprocess.com/groups/public/documents/instruction_manuals/d101402x012.pdf



Bibliography

1. lifes, Ratna, Ratna lifes, and View profile. 'HOW To Repair Your Self: Control

Valve Calibration'. Beyrepair.blogspot.com.au. N.p., 2010. Web. 18 Sept.

2015. Calibration control valve is needed to ensure that the control valve actuation can

produce responses as desired by the control system in a process. Actuation response is

meant to include the accuracy values, Linearity, and also the response time course.

Control valve as an actuator in a control loop has an important role in a process

meregulating. Meregulating failure in a process abnormality is an indication of an

ongoing process that if the shutdown effect.

2. Bibliography: Maintenanceresources.com,. 'Cashco Seat Leakage'. N.p., 2015.

Web. 18 Sept. 2015. There are actually six different seat leakage classifications as

defined by ANSI/FCI 70-2-1976. But for the most part you will be concerned with just

two of them: CLASS IV and CLASS VI. CLASS IV is also known as METAL TO METAL. It

is the kind of leakage rate you can expect from a valve with a metal plug and metal seat.

CLASS VI is known as a SOFT SEAT classification. SOFT SEAT VALVES are those where

either the plug or seat or both are made from some kind of composition material such as

Teflon.

3. G. LIPTAK, B. Process Control and Optimization

G. Liptak, Bela. Process Control And Optimization. 2nd ed. Florida: CRC Press,

2006. Print.The positioner is a high-gain plain proportional controller that measures

the valve stem position (to within 0.1 mm), compares that measurement to its set point

(the controller output signal), and, if there is a difference, corrects the error. The open-

loop gain of positioners ranges from 10 to 200 (proportional band of 10–0.5%), and

their periods of oscillation range between 0.3 and 10 sec (frequency response of 3–0.1

Hz). In other words, the positioner is a very sensitively tuned, proportional-only

controller. Positioners that are electronically and digitally controlled, or are intelligent

and are capable of self-diagnostics, communication on fieldbuses, and other advanced

features, are not discussed here, because they are described in detail in Section 6.12.

4. Process Industry Forum,. 2016. "Valve Terminology: Hysteresis, Deadband &

Linearity". Hysteresis When related to a valve, hysteresis is the difference between the

valve position on the upstroke and its position on the down stroke at any given input

signal. - See more at: http://www.processindustryforum.com/article/valve-

terminology-basic-understanding-key-concepts#sthash.ZphRyScw.dpuf

5. Process/industrial instruments and controls handbook

It used to be common practice in the industry to select valve size strictly as a function of

pipe size.Early efforts in the development of valve sizing centered around liquid flow.

Daniel Bernoulliwas one of the early experimenters who applied theory to liquid flow.

Subsequent experimental modifications to this theory produced a useful liquid-flow

equation.

http://www.processindustryforum.com/article/valve-terminology-basic-understanding-key-concepts#sthash.ZphRyScw.dpuf

http://www.processindustryforum.com/article/valve-terminology-basic-understanding-key-concepts#sthash.ZphRyScw.dpuf



8.Appendices

Appendix A

CONTROL VALVES TESTING CHECK SHEET

TAG NUMBER:

TYPE CHARACTERISTIC:

MODEL

SERIAL NO.

MANUFACTURER

FAIL POSITION:

INPUT SIGNAL

CLASS:

SIZE / RATING

INCH

ANSI (lb)

TRIM No / Cv

AS FOUND TEST:

TEST ITEM

MEDIUM TEST

PRESSURE (bar)

HOLDING TIME (Min)

ALLOWABLE

LEAKAGE( L/Min)

ACTUAL LEAKAGE (L/Min)

RESULTS

Seat Leak Test

Shell Test

STROKE TEST

RANGE (%)

OUTPUT

SIGNAL ( mA)

As Found As Left RESULTS Increa

sed Decreas

ed Error (%)

Increased

Decreased

Error (%)

0% 4.00

25% 8.00

50% 12.00

75% 16.00

100% 20.00



AS LEFT TEST:

TEST ITEM MEDIU

M

TEST PRESSURE

(bar)

HOLDING TIME (Min)

ALLOWABLE

LEAKAGE( L/Min)

ACTUAL LEAKAGE (L/Min)

RESULTS

Seat Leak Test

Shell Test

VALVE SERVICE RECORD:

PARTS

SERVICED

CORRECTIVE ACTION/REMARKS YES

NO

Actuator

Stem

Valve plug/ball

Seat Ring & retainer

Cage

Gasket

Packing

Bonnet

Valve body

TEST EQUIPMENT USED:

EQUIPMENT MODEL SERIAL NO CALIBRATION

DATE

NEXT CALIBRATION

DATE

TECHNICAL FINDING:

PERFORMED BY: VERIFIED BY:

Name:

Name:





Appendix B

Control Valve Leak Test Procedure TOOLS REQUIRED

Spanner Set

Workbench

Testing Flanges Pressure Gages

. Preparation Plan and Communicate the Task to be performed.

1. To ensure correct planning, arrangements and communication takes place prior to the test.

2. Check the location.

Ensure that the area is in a clean and tidy condition and free from obstacles.

To ensure that the task is performed on the correct Equipment in a safe environment.

Hydrostatic Test for Valve Body. To set up the Control Valve

1. Set the Control valve to its open position.

Manually, set the Control valve to half open or full open position.

Preparation for testing the integrity of valve seals. (i.e. stem packing, bonnet, and other seal on the valve body.)

2. Install test flange and test equipment at the downstream side of the Control Valve.

Attach the test flange and gasket to the Control valve downstream flange.

Tighten test flange bolts and nuts.

Attach the tubing, isolation valve; bleed valve, and pressure gauge.

To create a closed pressure system.

3. Install a test flange and test equipment to the upstream side of the Control valve.

Attach the test flange and gasket to the Control valve upstream flange.

Tighten test flange bolts and nuts.

Attach the tubing, isolation valve; bleed valve, and pressure gauge.

To create a closed pressure system. Preparation to inject test pressure supply to the Control valve body.

4. Prepare set-up before injecting pressure.

Close the isolation valve 2.

Close the bleed valve 1.

Open the isolation valve 1.

Open the pressure gauge valves 1 and 2.

Inject water through isolation valve 1 from a clean source of water.

Trapped air will be coming out as water is filling the system, close bleed valve 2 when no more air coming out.

Close isolation valve 1.

To make sure that no trap air is left inside the system.



Trapped air could contribute unstable pressure indication at the pressure gauges, thus can mislead the technician/inspector about the result of the test.

5. Apply pressure to the Control valve.

Remove the hose for clean water supply and install the hose coming from the hand pump.

Open the isolation valve 1.

Apply Hydraulic pressure of 1.5 times the operating pressure of the Control valve.

The pressure is maintained for about 2 minutes.

To perform the pressure test in order to determine leakage at stem packing, bonnet, and other seal parts.

6. Perform leak test on the Control valve.

Observe if there is any leak coming out at seal points (i.e. Packing, bonnet, etc.). (If test is done using pneumatic instead of liquid, use a leak test liquid – ex. Snoopy leak detector.)

Inspect the pressure gauge for loss of pressure. If the leak exist and cannot be corrected, the valve leak point need to be serviced again.

Record the result to determine if the valve seals does not leak.

7. After the test, empty the valve.

Close the isolation valve 1.

Open slowly the bleed valves 1 and 2.

After the pressure is low enough and safe, open the isolation valve 2 to drain the liquid.

This is to prepare for the next test.

If test not succeed need to service the valve and repeat the procedure.

8. Post activity

Disconnect control valve and perform housekeeping.

Test is completed.



LabVIEW Flow meter

Valve % Flow rate Flow rate Deviation

0 1.28389 0

5 1.2545 0

10 1.28545 0

15 1.28701 0

20 3.3016 1.671

25 6.424 4.29

30 9.3612 6.71

35 12.0147 8.91

40 14.244 10.78

45 16.235 12.43

50 17.9138 13.83

55 19.132 14.87

60 20.29 15.84

65 21.2123 16.61

70 22.0864 17.35

75 22.7876 17.93

80 23.375 18.36

85 23.82 18.76

90 24.098 19.04

95 24.3268 19.22

100 24.575 19.44

Table 7: Flow rate Data from Labview and Flow meter (Magnetic Flow Meter)

Flow rate Step

0 0

4.763 20

11.74 40

15.69 60

17.74 80

18.85 100

18.85 100

17.74 80

15.69 60

11.74 40

4.763 20

0 0 Table 8 : Hysteresis data 1



Flow rate Step

0 0

4.763 20

11.74 40

15.69 60

17.74 80

18.85 100

18.85 100

18.02 80

16.14 60

12.87 40

6.92 20


Flow rate Step

0 0

6.87 20

10.53 40

15.44 60

17.31 80

17.89 100

17.89 100

17.4 80

15.69 60

10 40

6.34 20


Flow rate Step

0 0

3.2 20

6.52 40

9.71 60

14.8 80

15.7 100

15.7 100

15 80

14.2 60

9.89 40

5.08 20


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