control system module 1 unit 4 - nebula.wsimg.com
TRANSCRIPT
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FINAL CONTROL ELEMENT
ZERY ENGINEERING INSTITUTE OF TECHNOLOGY
CONTROL SYSTEM MODULE 1
UNIT 4
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Table of Contents
Introduction to Control Valves Valve Type
Valve Body Bonnets
Control Valve Packing
Control Valve Performance
Valve Type And Characterization
Actuators Control Valve Accessories
MASONEILAN 41000 Series Control Valves MASONEILAN SVI® SMART VALVE INTERFACE
High-Capacity Rotary Valves
FIELDVUE digital Valve controllers
Rotork electric valve actuators
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Introduction to Control Valves
Process plants
consist
control loops
designed to keep
required operating range
pressure temperaturelevelflow
receivesinternally creates
disturbances
reduce
controller
decides
what must be done
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final control element
most common process control industries
control valve
manipulates
flowing fluid
gas steam chemical compounds
compensate
load disturbance
keep
regulated process variable
close
desired set point
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control valve assembly
consists
valve body internal trim parts
valve accessories
positioners
actuator
provide
motive power
transducers
supply pressure regulators
limit switches
manual operators
snubbers
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VALVE TYPES
check valves stop valves
GLOBE VALVES
GATE VALVES
BUTTERFLY VALVES
BALL VALVES
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GLOBE VALVES
most common
in existence
common types
straightflow
angle-flow
cross flow
Single-Port Valve Bodies
Double-Ported Valve Bodies
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GLOBE VALVES
Single-Port Valve Bodies
most common
body style
simple in construction
various forms
globeanglebar stock
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GLOBE VALVES
Double-Ported Valve Bodies
higher capacity
than single-ported
smaller actuator
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GATE VALVES
are used
minimum restriction
is desired
not suitable
for throttling
classified as
RISINGSTEM NONRISING-STEM
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BUTTERFLY VALVES
light in weight
relatively small
relatively quick-acting
can be used for throttling
has
resilient seat
butterfly disk
stem
packing
notched positioning plate
a handle
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BALL VALVES
quick-acting
90-degree turn to operate
planetary gear operated
found in the following systems
seawater
sanitary
trim and drain
air
hydraulic
oil transfer
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Valve Body Bonnets
provides a means of
mounting
actuator
to the body
houses
packing box
Typical Bonnet, Flange,
and Stud Bolts
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Valve Body Bonnets
not have
rotary valves
globe-style control valve
made
same material
valve body
the high pressure
screwed into
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Valve Body Bonnets
Extension Bonnets
used
high low
temperature service
protect
valve stem packing
cast fabricated
better high-temperature are preferred for cold
service
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Valve Body Bonnets
Bellows Seal Bonnets
used
no leakage
can be tolerated
along the stem
process fluid
toxic
volatile
radioactive
highly expensive
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Control Valve Packing
most control valves
use
packing boxes
with the packing retained
adjusted by
flange stud bolts Single PTFE V-Ring Packing
Polytetrafluoroethylene (PTFE)
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Control Valve Packing
packing materials can be used depending on the service conditions
Comprehensive Packing Material Arrangements
for Globe-Style Valve Bodies
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PTFE V-Ring
Control Valve Packing
Plastic material
inherent ability
minimize friction
Molded in V-shaped
spring loaded
self-adjusting
In packing box
lubrication not required
Resistant to most
known chemicals
except molten
alkali metals
Requires extremely
smooth stem
temperature limits:
−40 to +450_F (−40 to +232_C)Not suitable for nuclear service
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Laminated and Filament Graphite
Control Valve Packing
Suitable for
high temperature
nuclear service
where low chloride
content is desirable
leak-free operation
Provides
long service life
produces
high stem friction hysteresis
Impervious
hard-to-handle fluids high radiation
Lubrication not required
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PTFE V-Ring
Single PTFE V-Ring Packing
Single PTFE V-Ring Packing
uses
coil spring
between
packing packing follower
pressure
not exceed 20.7 bar (300 psi )
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PTFE V-Ring
ENVIRO-SEAL_ PTFE Packing
advanced packing
method
utilizes
compact, live-load
spring
environmental applications
suited to
up to 51.7 bar and 2320C (750 psi and 4500F).
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ENVIRO-SEAL Duplex Packing
Provides components
PTFE graphite
yield
low friction low emission
fire-tested solution
temperatures up to 2320C (4500F).
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KALREZ_ Packing
Fisher valve only
use
up to 24.1 bar and 2040C
(350 psi and 4000F)
non-environmental services up to
103 bar (1500 psi).
with ZYMAXX
carbon fiber-reinforced TFE
suited to 2600C
(500 0F)
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ENVIRO-SEAL_ Graphite ULF
Laminated and Filament Graphite
Designed for
applications at
excess of 232_C (450_F).
incorporates
very thin PTFE layers
inside the each side
packing rings
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ENVIRO-SEAL_ Graphite for Rotary Valves
Laminated and Filament Graphite
from −60C to 3160C
(200F to 6000F)
pressures to 103
bar (1500 psi)
ENVIRONMENTAL PROTECTION AGENCY
500 ppmv EPA
leakage criteria.
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Control Valve Performance
Process Variability
non-uniformity
in the raw materials processes
causes
variation
above below
set point
bell-shaped normal distribution.
typically follows
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Process Variability cont.
measure
tightness of control
expressed
percentage
Reducing
is a key
achieving
business goals
of the set point
+/-2 sigma band
statistically derived
values on this distribution
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Process Variability cont.
reducing
studies control loops
test productsunder dynamic
process conditions
performed
flow lab
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Process Variability cont.
reducing
optimized developed as a unit
control valve assembly
design considerations
Dead band
Actuator/ positioner design
Valve response time
Valve type and sizing
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Dead Band
range through which
input signal can be varied,
withoutchange in the output signal.
controller output (CO)
process variable (PV)
causes
friction backlash
loosenessslack
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Dead Band cont.
Valve A
process variable
responds well
low as 0.5 %
Valve B
input signal
great as 5%
Valve C
considerably worse
great as 10%
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Actuator-Positioner Design
Actuator Positioner
must be considered together
greatly affects
static performance (dead band) the dynamic response
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Positioner
allow for
precise positioning accuracy faster response
to process upsets
most important characteristic
high gain
static dynamic
Sensitivity of the device
(0.125% or less)
power amplifier function
preamplifier
relay spool
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Valve Response Time
measured
T63 (Tee-63)
time from initiation
input signal
output reaches 63%
corresponding change
dynamic time
dynamic characteristics
positioner
and actuator combination
static time
dead time
Dead band
friction
valve body actuator positioner
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Valve Response Time Summary
Valve Response Time
actuator
spring-and-diaphragm
piston
faster
small signal
slower
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Valve Type And Characterization
valve
sufficient size
pass the required flow
inherent characteristic
relationship between
valve travel
flow capacity ( flow or Cv).
differential pressure drop
constantInherent Valve Characteristics
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Inherent Valve Characteristics
linear
constant inherent
valve gain
range
full
quick-opening
greatest
largest lower end
equal percentage
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Inherent Valve Characteristics
useful
more important
flow characteristic
entire process
pressure drop
Installed flow characteristic
across the valve
constant change naturally
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Installed flow characteristic
obtained under
laboratory conditions
by placing
entire loop
in operation some nominal set point no load disturbances.
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Installed flow characteristic
Loop gain
should not vary
more than
4-to-1 ratio
(From Control Valve Dynamic Specification, Version 3.0, November
1998, EnTech Control Inc., Toronto, Ontario, Canada )
0.5 to 2.0 gain limits
is widely accepted
gain limits from 0.2 to 0.8
Some industry experts
which is still
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Installed flow characteristic
control range
varies dramatically
valve style
globe valve
wider
butterfly valve
narrowest
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Valve Sizing
Oversizing
too much gain
less flexibility
in adjusting the controller
operate
more frequently
at lower valve openings
seal friction greater
greatly exaggerate
process variability
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Control Valve Actuators
Pneumatically operated electric hydraulic manual
most commonly
specified
dependability
simplicity
of design
piston actuators
provide
high stem force output
more complex more expensive
than pneumatic
offer advantages
low ambient temperatures
where no air supply
large stem forces are needed
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Diaphragm Actuators
use air supply from
controller positioner
other source
Various styles include
direct acting reverse-acting
reversible
Net output thrust
difference
diaphragm force
spring force
Molded diaphragms
provide
linear performance
increased travels
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direct acting
extends actuator stem
increasing air pressure
pushes down diaphragm
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reverse-acting
retracts actuator stem,
increasing air pressure
pushes up diaphragm
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air pressure pushes
down on diaphragm
open or close
depending on orientation
lever on the valve shaf
reversible
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Piston Actuators
pneumatically operated
high-pressure plant air
to 150 psig
furnish
fast stroking
speeds
maximum thrust output
double acting
maximum force in
both directions
spring return
fail-open fail-closed
operation
provide
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Electrohydraulic Actuators
require only
electrical power
electrical input signalisolated locations
ideal for
precise control
valve plug position needed
pneumatic supply
not available
Control Valve with
Double-Acting Electrohydraulic
Actuator and Handwheel
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Manual Actuators
Useful where
automatic
not required
still necessary
ease operation
good manual
control
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Rack and Pinion Actuators
provide
compact economical
solution
for rotary shaft valves
typically used
on-off applications
process variability
not a concern
Typical Rack and Pinion
Actuator
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electric motor
Electric Actuators
designs use
gear reduction
move the valve
more expensive
than pneumatic
performance levels
same
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Control Valve Accessories
digital valve controllers
analog positioners
boosters
other control valve accessories
Positioners
take an input signal
process controller
valve travel
convert
Pneumatic
Analog I/P
Digital Controller
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Pneumatic
Positioners
(usually 3-15 psig)
supplied
pneumatic signal
translates
required valve position
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Analog I/P
Positioners
translates
required valve position
uses
electrical current
usually 4-20 mA
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Positioners
Digital Controller
functions
same as
Analog I/P
differs in
electronic signal
conversion
digital
Digital Non-Communicating
HART
Fieldbus
Modern Control Valves
Utilizing Digital Valve
Controllers
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Digital Controller
HARTDigital Non-Communicating
current signal
(4-20 mA)
supplied
powers
electronics
controls
output
digital communication
same as
two-way
capable
Fieldbus
receives digitally
based signals
positions valve
digital electronic circuitry
coupled to mechanical components
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Other Control Valve Accessories
top-mounted handwheel
direct-acting
Diaphragm actuator
reverse-acting
adjustable
travel stop
used as
manually close
push-down-to-close
used as
adjustable
travel stop manually close
push-down-to-open
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Limit Switches
operate discrete inputs
distributed control system
signal lights
solenoid valves electric relays
alarms
cam-operated
two four
individual switches
operatedvalve stem
by movement of
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Solenoid Valve Manifold
can be used
double-acting pistons single-acting diaphragm
actuators
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Supply Pressure Regulator
commonly called airsets
reduce plant air supply
valve positioners other control equipment
mounts
integrally to the positional
to the actuator
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Fail-Safe Systems for Piston Actuators
actuator piston
moves
top bottom
cylinder
pressure falls
below a pre-determined value
The volume tank
provides loading pressure
pressure fails
moving the piston
desired position
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Electro-Pneumatic Transducers
receives
direct current input signal
uses
torque motor
nozzle-flapper
pneumatic relay
convert
proportional pneumatic output signal
Electro-Pneumatic
Transducer Mounted on a
Diaphragm-Actuated Control
Valve
operate
without
additional boosters or
positioners
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Electro-Pneumatic Valve Positioners
used
electronic control loops
operate
diaphragm control
valve actuators
4 to 20 mA DC input
receives
convert to a pneumatic output signal Electro-Pneumatic
Positioner on Diaphragm Actuator
Split-range operation
can provide
full travel of the actuator
portion of the input signal
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41000 Series Control Valves
A Complete Line of Heavy Duty, Balanced,
Cage Guided, Globe Valves with Noise Control
Lo-dB® Trim
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41000 Series Control Valves
Broad Temperature Rangesfrom -196°C to +566°C.
Higher Allowable Pressure Drops
exceptional dependable
performance
wide range of pressure drops
Greater Capacity with Low Recovery
attained
minimum
pressure recovery
critical flow (FL) factors
indicated by
High-Performance
Materials are Standard
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General Data
Standard Valve
(41300, 41400, 41500, 41600 and 41900)
Body
CV ratio :
100:1
standard capacity trim50:1
Bonnet
extended
stud bolted
Trim
cage plug
cylindrical ported
Lo-dB
pressure balanced cage
guided with metal
PTFE graphite
seal ring
Flow Characteristic
linear
equal
percentage
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Optional Trim Types
Single Stage Multi-hole
Low Noise and
Cavitation Protection
DN 50 - DN 100 Shown
(2" - 4")
Multi-hole, Low
Noise and Cavitation
Protection
Trim with Internal
Diffuser
DN 150 - DN 400
Pressure Energized Seal
DN 150 - DN 400 Shown
(6" - 16")
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Body Construction 1 Valve plug stem
2 Packing flange stud
3 Packing flange nut
4 Packing flange
5 Packing spacer
6 Packing7 Bonnet
8 Valve body nut
9 Plug pin
10 Valve body gasket
11 Seal ring type
12 Plug spring (41400 only)
13 Seat ring
14 Seat ring gasket
15 Valve plug
16 Cage
17 Flat spring ( 6" to 16")18 Body
19 Retaining ring (41400 only)
20 Auxiliary plug (41400 only)21 Valve body stud22 Guide bushing
23 Packing follower
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Temperature Range/Seat Leakage
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Cv and FL versus Travel
Standard Trim (Single Stage) Models 41411, 41511, 41611 and 41911
Flow Characteristic : LINEAR
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Allowable Pressure Drops for 41300 Series (bar)
Flow To Open
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Dimensions (mm)
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Dimensions (mm) cont.
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Dimensions (mm) cont.
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Dimensions (mm) cont.
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MASONEILAN SVI®
SMART VALVE INTERFACE
digital valve positioner process controller
configured operated
locally remotely
of local pushbuttons
digital displayValVue product
HART
single-loop PID controller
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MASONEILAN SVII®
SMART VALVE INTERFACE
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basic functions
Remote display
of valve position
Remote calibration of the SVI
Remote configuration of the SVI
Remote operation of the SVI
Manual control
of valve position
Perform valve diagnostics
Recall previous test results
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SVI Features and Functions
Precision valve
positioning control
Advanced valve
diagnostics
Automatic setup
and tuning
Local operation/calibration/
configuration
Two-way data communication
Remote operation/calibration/
configuration/diagnostics
User-configurable tight
shutoff adjustment
Optional PID controller
User-adjustable
response times
Direct or reverse
acting operation
Compatible with air-to-
close or air-to-open
actuators
Span and zero configurable
for split-range operation
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Performance
Specifications
Performance Specifications
(Positioner Mode Only)
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Performance
Specifications (cont.)
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Electrical Safety Specifications
Electrical Safety Design Specifications
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Principle of Operation
electropneumatic valve positioner
SVI accepts a 4-20 mA
compares
to the valve position
Difference conditioned
control algorithm converted pneumatic signal
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SVI Controller
accepts
local control setting
primary process
measurement
is fed
voltage signal
of 1 to 5 V dc
4-20 mA signal
difference conditioned
PID controller position control
algorithm converted
pneumatic signal
boosted pneumatic relay drives actuator
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High-Capacity Rotary Valves
V150 Series B Valve
for throttling
suitable
on-off service
used
full 0 to 90 degree
ball rotation
provides
high-capacity control of
liquid
gas
steam
fibrous slurries
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The Vee-Ball® Valve Family
Easy Installation
exposed flange studs
integral flanges
eliminate
High Rangeability
Flow coefficient 300 to 1
Reduced Maintenance
Costs
have interchangeable trim parts
Easy Seal Inspection...
Seals can be inspected
without removing the actuator
disassembling the valve
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Body Materials, End Connections, and Ratings
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Maximum Inlet Pressure for CW2M (Hastelloy C) Valve
Bodies
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Flow Coefficients
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FIELDVUE digital Valve controllers
provide
highly accurate
positioning
as well as
high-speed stable valve response
output capacity
simplified schematics
eliminate
boosters quick releases
Fisher® FIELDVUE® DVC5010f
Series digital valve controller
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Cutaway View of
FIELDVUE® Type DVC5010f
Digital Valve Controller
Instrument Description
DVC5000f Series digital valve controllers
interoperable
process controlling
communicating
microprocessor-based
digital-to-pneumatic
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primary function
converting
digital input signal
pneumatic output
DVC5000f Series digital valve controller
using
FOUNDATION fieldbus
access to information
critical to process operation process control
principal component of the process
control valve
health ofinstrument
actuator
valve
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Principle of Operation
FOUNDATION Fieldbus Communication
digital two-way
communication system
interconnects
"field" equipment
transmitters
valve controllers
process controllers
local-area network (LAN)
capability
distribute
control application
across the network
retains
features of analog systems
intrinsic safety
options
standardized physical
interface to the wire
bus powered devices on
a single wire pair
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Digital Valve Controller Operation
DVC5000f Series digital valve controllers
have
single master module
easily replaced
without disconnecting
wiring tubing
submodules
current-to-pneumatic
(l/P) converter
printed wiring
board assembly
pneumatic relay
can be rebuilt by
replacing the submodules
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Digital Valve Controller Operation
input
routed
terminal box
single pair of wires
printed wiring board
read by the microprocessor converted analog l/P drive signal
processed by a digital algorithm
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DVCSOOOf Series Digital Valve Controller Assembly
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Rotork IQ & IQT Range
electric valve actuators
Fit for Life
Design simplicity
double sealing
watertight enclosure
infra-red set-up
comprehensive protection systems
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Rotork IQ & IQT Range
electric valve actuators
Simple commissioning
“point and shoot” IQ Setting Tool
torque levels
position limits
using
settings
control
functions
indication
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Rotork IQ & IQT Range
electric valve actuators
Simple troubleshooting
Access comprehensive
real-time
diagnostic help screens
on-board data
Logger records
alarm
valve torque profile
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IQ 3 phase performance summary
Performance data