Presentation on Smart Positioner/

Volume Booster/Quick Exhaust

Valve and means of achieving Fail
Open/Close position of
Pneumatically operated Dampers.

By
Harish Sharma

24-10-2020
 I/P CONVERTER

• In the Current to Pressure converter, we give input current signal as 4 – 20

mA .  We also give a continuous supply of 1.4 Kg/cm2 to the Flapper Nozzle
assembly. As we give input current signal, Electromagnet gets activated. If the
current is more, then the power of magnet will get increased. The Flapper of
the Flapper-Nozzle instrument is connected to Pivot so that it can move up
and down and a magnetic material was attached to other end of flapper and
it is kept near the electromagnet.
• As the magnet gets activated. the flapper moves towards the electromagnet
and the nozzle gets closed to some extent. So the some part of 20 P.S.I
supplied will escape through nozzle and remaining pressure will come as
output.
• If the current signal is high, then power of the magnet will increase, then
flapper will move closer to the nozzle, so less pressure will escape through
nozzle and output pressure increases.
• In this way the output pressure will be proportional to the input current.
For the input current of 4 – 20 mA we can get the output pressure of
0.2- 1.0 Kg/cm2.

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 VALVE POSITIONERS

• The fundamental function of a positioner is to deliver

pressurized air to the valve actuator, such that the position of
the valve stem or shaft corresponds to the set point from the
control system. Positioners are typically used when a valve
requires throttling action.
• It accepts a low pressure air control signal/4-20 mA signal and,
by using its own higher pressure input, multiplies this to
provide a higher pressure output air signal to
the actuator diaphragm, if required, to ensure that the valve
reaches the desired position.

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 TYPES OF VALVE POSITIONERS

• Pneumatic Positioner :These are conventional Positioner which were used in Combination
with I/P converter. 4-20 mA signal was fed to I/P converter alongwith 1.4 Kg/cm supply air.
Providing an output of 0.2-1.0 Kgcm2 output depending on the signal. The I/P were with
Direct Acting or reverse acting version. The 0.2-1.0 Kg/cm signal was fed to Pneumatic
Positioner along with Supply air at 4-6 Kg/cm2.
• Analog Positioners : Here, the input signal is electrical, rather than pneumatic.
• Smart valve positioners : These are digital valve controllers, microprocessor-based, current
to pneumatic instruments with internal logic capability. They are designed to convert a
current signal to a pressure signal to operate a valve. The main reason digital positioners
are popular is that they can do much more than just control the position of the valve. The
newest positioners on the market can also collect data about the valve to automatically
alert users about how the valve and its assembly are performing, and even aid
in diagnostics and maintenance. Since they have fewer mechanical moving parts, digital
positioners last longer than their traditional pneumatic and analog counterparts. Plus, they
don’t bleed any air while the valve is at rest, which reduces energy consumption.

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 PNEUMATIC CONTROL VALVE OPERATION

• Large control valves are frequently driven by pneumatic actuators requiring a

significant amount of volume to operate. This poses a problem when fast valve
opening or closing times are required due to the limited air capacity of many valve
positioners. The speed of a cylinder is determined by where the incoming pressure
can overcome the resistance of the load. However, there is a hidden force built into
that resistance. That force is the energy needed to get the air on the opposite end
of the piston out. The tubing and directional valve restrict this outgoing air until it
reaches the exhaust port.
There are two methods to increase the flow of the actuator:
• 1. Either Increasing the Air flow rate input to the Actuator.
• 2. Or increasing the Air flow rate exhaust from the Actuator.
In these cases, volume boosters and quick exhaust valves are used to
provide quick positioning performance.

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Increasing the Air flow rate INPUT to the Actuator

Volume Booster - Function

• Volume boosters are used together with positioners to increase the positioning speeds of
pneumatic actuators. They influence the process to vent or fill the actuator with air, which
causes the control valve to open or close more quickly. The Volume booster is mounted
between the positioner and actuator. This way, the volume booster supplies the actuator with
an air flow output whose pressure corresponds exactly to the signal pressure of the positioner,
with the exception that it has a much higher volume i.e. a pneumatic air volume
booster reproduce a low flow control signal with a higher regulated flow output pressure.

This pneumatic signal controls the pressure into and out of the booster, while allowing the
booster to flow the maximum volume of the supply line.
The regulated output of a pneumatic air volume booster can be any of the following:

a. A direct reproduction of the pneumatic control signal

b. A multiple of the pneumatic control signal 
c. A fraction of the pneumatic control signal

The volume booster ratio is the multiplier or divider of signal pressure to output pressure. For
example, a gain of 2, turn a 0.2 bar signal to 0.4 bar output pressure
Note, however, the output pressure can never exceed the supply pressure to the booster.

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Increasing the Air flow rate INPUT to the Actuator

Volume Booster – Working Principle

• The working principle is shown in the adjoining figure.
• It is provided with an air supply (typically 2-4 bar) and an input signal pressure which in fact is the
Positioner output. The booster admits air to, or vents air from, the output to maintain a constant
output/input ratio.
• A unity gain booster is shown in the above figure. It consist of two equal area linked diaphragms,
which together operate a needle and ball valve arrangement. The low-volume input signal is
applied to the upper diaphragm and the output pressure to the lower diaphragm. If output
pressure is lower than inlet pressure, the diaphragm is pushed down, closing the needle valve and
opening the ball valve to pass supply air to the load and increase output pressure. If the output
pressure is high, the diaphragm is forced up, closing the spring loaded ball valve and opening the
needle valve to allow air to escape through the vent and reduce output pressure. The amplifier
stabilizes with output and input pressures equal. The booster balances when forces on the two
diaphragms are equal and opposite. Equal-area diaphragms have been used in the unity gain
amplifier.
• The area of the input diaphragm in the Volume Booster shown in bottom figure is twice the area
of the output diaphragm. For balance, the output pressure must be twice the input pressure,
giving a gain of 2.
• In general, the amplifier gain is given by:
• Gain = Input area / output area.

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 Increasing the Air flow rate INPUT to the Actuator

Volume Booster – Control scheme of Fail Open/Close Damper

• The attached control scheme show use of Volume Booster (Item no. 24)n a
control Damper with Fail safe position as Open/close. The Control scheme is
for WHR unit for HRD Process Platform Project (#0812).

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Increasing the Air flow rate OUTPUT of the Actuator

Quick Exhaust Valve – Function

The Function of QEV is to provide rapid exhaust of controlled air when placed directly
onto an air cylinder after the control valve. They increase cylinder speed by eliminating
most of the back pressure of the exhaust air, permitting it to vent directly to
atmosphere. The are particularly helpful in applications where the lines connecting
valves and cylinder are unusually long.
In a cylinder application, a quick exhaust valve is a simple shuttle valve. This valve allows
air that is coming out of a cylinder to be directed to atmosphere instead of flowing back
through the directional valve. While this may seem like a simple change in the air
release, it has a big impact on performance. 

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Increasing the Air flow rate OUTPUT of the Actuator

Quick Exhaust Valve – Working Principle

• QEV is a two position, three port shuttle valve. The way it works is simple. Air is made to pass
through from a control valve into the inlet port of QEW which is directly mounted onto the
cylinder ports.
• Supply port P is fed with Air from final control element. The out put port A is directly fitted on to
the cylinder port. The exhaust, R is left open to atmosphere(Generally fitted with Silencer to
reduce the noise of the bleeding air)
•During Normal operation, the Port P supplies the air to Rod End side of the Cylinder. Port P exerts
pressure on the diaphragm , closes the port R and air is fed through Port A to the Cylinder. As
soon as the direction control vale changes position, the, the Air is supplied to the Cap/Head port
of the cylinder, the rod end side gets pressurized, the diaphragm closes port P and the cylinder is
exhausted through Port R directly to the atmosphere.
•Since the air is pressurized, it is able to move the piston thus extending the rod which in turn
compresses the spring until the rod is completely extended. When air is exhausted from the inlet
port of this valve, it is sealed by the Buna-N poppet which shifts as a result and the exhaust port
opens up to the cylinder. The air is then allowed to pass onto the atmosphere from the exhaust
valve.
•Port size of a typical QEV is :
Signal (Port P) – 3/8”
Exhaust/Output (R/A) – 3 /4”

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 Increasing the Air flow rate OUTPUT of the Actuator
Quick exhaust valve – Control scheme of Fail Open/Close Damper
• The attached control scheme show use of Quick Exhaust valve(Item no. 30) on a
control Damper. The Control scheme is for Condensate Heater (42F-101) for ENOC
PROCESSING COMPANY(071973C).

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 Methods to achieve Fail Safe Open/close Position
Meaning and methods of achieving of Fail Safe Position
• A fail safe status is how the Damper should operate when there is a loss of power
(electrical/Instrument air) or signal. The Damper fail position is a safety precaution that
protects our process in emergency situations.
• It is important to remember that valves are generally pneumatic, meaning that their
function is based on air pressure. Air has to be added in order to open or close the valve,
depending on how it is set required. The air pressure acts on piston of an actuator,
creating/enabling force to bring the Damper Blade in desired position.
• The fail safe open/Close for Pneumatic Operation can be achieved by three following
means:
• A. Single acting Spring return Actuators.
• B. By an external Volume Tank/Accumulator.
• C. By means of Counter weight.
The Damper Data sheet /Specification govern the Type of Fails safe method to be adopted.

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 Methods to achieve Fail Safe Open/close Position
Single Acting Spring Return Actuator

• The Single acting spring return actuator is a relatively simple design; compressed air drives
a piston/piston Rod inside a cylinder which is connected through Linkage to Damper shaft.
The pneumatic spring return actuator is one of the most widely used fail-safe actuators in
the world.  This is primarily because of the pneumatic actuator simplicity of operation and
low initial investment particularly if there are air lines already available.  In addition to low
initial cost there are many other reasons to consider pneumatic actuators for failsafe
applications.  Pneumatic actuators are light weight, fast acting, not affected by duty cycle,
readily available, easy to install, wide torque range to select from and there are numerous
vendors to assist with selection. 
• This method(if followed) to included during the design phase of Damper, as its affects the
actuator model selection and Pneumatic actuators being bought-outs . Further, the Fail
safe position (Open/Close) to be clearly specified to Vendor, particularly for damper
requiring flexible sealing.

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 Methods to achieve Fail Safe Open/close Position
Double Acting Actuator with Counter weights
• The Double acting actuators are used for fail safe operation with the help of external counter
weights mounted on Damper shaft. During normal operation, the double acting actuator
positions the damper blade as per command Signal.
• During Fail Safe condition, on failure of Instrument air / or falling below the minimum
Instrument pressure, the Double acting actuator, is exhausted by means of Pilot operated
pneumatic direction control valves. The Counter weight mounted on Damper shaft than
drive the damper to fail safe position.
• The Counter weight add on to the Damper design torque and affects the Shaft/Actuator
sizing. This method also to be included in the design phase of Damper as its affects the
actuator sizing and pneumatic actuators being bought-outs with long lead time. Further, the
Fail safe position (Open/Close) to be clearly specified to Vendor, as Counter Weight for Fail
close position are much higher than those required for fail open position.
• Also counter Weight are mounted on the Damper Shaft and hinder the passage on access
platform. The movement of damper hinder walkway during operation also poses HSE issues

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 Methods to achieve Fail Safe Open/close Position
Double Acting Actuator with Volume Tank
The Double acting actuators are used for fail safe operation with the help of Volume tank. The
volume tanks acts as a buffer during Instrument Air failure
During normal operation, the double acting actuator positions the damper blade as per command
Signal.
• During Fail Safe condition, on failure of Instrument air / or falling below the minimum Instrument
pressure, the one port of Double acting actuator is exhausted by means of Pilot operated
pneumatic direction control valve whereas the other port is pressurized by the volume Tank.
• The volume tank need to be design for no of strokes of the Actuator as per Damper Data
sheer(minimum 3 full stroke operation).
• This method does not effect the damper design and in case where, one missed, the fails safe
requirement during design phase, the same can be included as an after thought with volume tank
with minor modification in Control scheme.
• The Volume Tank can be mounted anywhere near the Damper/Control Panel and also does not
hinders the walkway during operation also does not poses HSE issues

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THANK YOU