How To Do Maintenance of Control Valve Which Is Stuck in Field

24/02/2024, 23:48 How to Do Maintenance of Control Valve Which is Stuck in Field?
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How to Do Maintenance of Control

Valve Which is Stuck in Field?
by Shiv Kumar
In this article, you will learn how to do maintenance of control valve which
is stuck in the field at a fixed position, and its detailed procedure.
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Table of Contents
1. Required Tools
2. Maintenance of Control Valve
3. Control Valve Inspection
4. Why does a control valve get stuck, if the control valve is having stiction?
5. Critical Components of Control Valve
6. How to Repair a Control Valve having a Stiction issue?
Required Tools
https://instrumentationtools.com/maintenance-of-control-valve/ 1/16
Hand tools such as spanner & Screw Diver
Digital Multimeter
Handheld configurable HART communicator if positioner is smart.
Loop calibrator or multipurpose calibrator to feed 4 to 20 mA signal

Cloth for cleaning
Standard fittings with tubing to check actuator movement
Maintenance of Control Valve
If Valve not operating properly follow the below points
1. Inspect the control valve along with its associated accessories.
2. Inspect for physical damage or air leakages. Fix them if any problems are
detected.
3. Apply constant air supply to the control valve.

4. Inspect instrument air supply to valve positioner coming from Air Filter
Regulator.
5. Ensure the set pressure of the Air Filter Regulator is matching with the
value specified in the Control Valve datasheet.
6. If air pressure is less than required then the valve moves very slowly.
7. If air pressure goes high or more than required then there is a chance of
actuator damage.
8. To avoid this damage & slow working kindly adjust the air pressure to
the required value.
9. Evaluate the condition of the isolation valve located in the air supply
header in absence of an air supply.
10. Keep the isolation Valve in closed condition.
11. Send the confirmation for control valve operation from the control room
based on field condition.
12. Check the current signal on the electro-pneumatic positioner, if the valve
remains stationary.
13. If there is no current signal available, check cable connections by
referring loop drawing on both the field side and the marshaling cabinet
side.
···
14. Inspect the fuse condition in the marshaling cabinet. Replace the fuse
with an equal rating if it is blown.
15. Check the condition and resistance of the cable once again if there are
any issues.
16. If there is any issue with the cable pair, replace a new good cable with an
equal rating as per design.
17. Provide 0 to 100% instruction from the control system to perform valve
stroke checking tests and ensure accurate control valve feedback in
SCADA or HMI.
18. Change the configuration or feedback setting if feedback is not available
even after a healthy valve stroke is confirmed by the system command.

19. Two valve feedback concepts such as open feedback closed feedback,
and another one is analog feedback from 0% to 100% which depends
upon valve design.
···
20. The problem with analog feedback if occurred can be resolved by control
valve calibration.
21. Check system interlocks for analog output signals within the program, &
control system permissive conditions.
22. The control system doesn’t transmit any instruction for incorrect logic,
and no stem movement occurs in the control valve.
23. Calibration of a valve addresses if any problems occurred within the
control valve stroke.
24. After calibration is complete check the valve stroke again, & check mA to
the valve positioner’s input for stroke problem if exists.
25. Send some commands to the control system and check the field current
in mA in an electro-pneumatic positioner or I-P converter.
···
26. If any problem is found in the analog output channel within the control
system, then replace the faulty analog I/O module with the new module
of the same specification.

27. Check the working condition of the air filter regulator.
28. Check the operating condition of the volume booster, airlock relay, trip
valve, vent port, and solenoid valve for subsequent addition.

29. Check for any kind of blockages identified and ensure for no blockages
by arresting.
30. Replace respective components if any significant problems were
identified.
31. Ensure that the whole tube line is clear of choking.
···
32. Ensure the absence of obstruction, and replace it if major issues are
identified.
33. Check and make sure no issues are present, if found any issues replace
them.
34. Check the condition of the valve positioner, & its output.
35. Calibrate and repair the valve positioner if there is no output signal.
36. Refurbish a control valve every time and calibrate a positioner
accordingly with reference to calibration instructions, since the
calibration procedure of each model varies whit is not the same.
37. If there is any functional error in the valve positioner then remove and
calibrate once again by ensuring the control valve’s stroke checking after
calibration is done.
38. If the above possibilities are not satisfying true then the problem is
located in the actuator or valve body.
39. If any problems occurred in the control valve function, remove all tubing
and test control valve movement by supplying external air to the
actuator directly.
···
40. Perform manual valve operation to relieve the stuck state.
41. Remove the actuator stem, & stem connection to check the actuator
function to determine the point of the issue.

42. Verify whether the actuator is passing or not since most control valve
comes with air-passing ports to check the deterioration in the
diaphragm.
43. If the actuator is experiencing passing problems conduct an overhaul on
the actuator.
44. If the actuator is not operating well remove the cap and check the plate,
spring, and other components within the control valve actuator.

45. Inspect all internal actuator components.
Control Valve Inspection

During calibration inspect the following
1. O-rings,
2. Moving components such as cam, lever, spring, etc.
3. Diaphragm pressure Gauges
4. Cracks
5. Nozzle & its Flapper.
6. Supply air leakage.
7. Ensure that Electric coils and electronic cards in I-P positioners are kept
dry, & moisture free.
Why does a control valve get stuck, if the control

valve is having stiction?
1. Another problem is that the control valve loop is referred to as stiction.
2. Basically, stiction means the combination of the words “stick” and
“friction.”
3. This condition allows the valve to retain in a constant position, without

allowing it to travel freely like a valve Dead band.
4. When a Stiction problem in a valve occurs the valve movement needs
greater effort.
5. This increased force makes the valve overshoot its position and dead
band set-point, which makes the valve stacked in a new or incorrect
position.
6. The Valve Stiction problem exists mostly in all preset mode control loops,
revealing a continuous cycle pattern in controller output and a square
wave pattern in process variables, resulting in process disruption and
valve tears.
Critical Components of Control Valve

Critical Components of the Control Valve Subjected to Inspection
1. Actuator Diaphragm
2. Actuator Shaft
3. Trim elements such as Plug, Seat, Cage, and Stem.
4. Bonnet Gland Packing Box
5. Gasket Seating Surface
6. Body Wall NDT Test
7. Valve Positioner Condition
8. Valve body Stud Bolts and Nuts

9. Actuator Spring
10. Hand-Wheel (if installed)
11. Flange Gasket Surfaces
How to Repair a Control Valve having a Stiction

issue?
Follow the below points to repair a control valve.
···
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1. The valve actuator and positioner must be sized correctly to change the
necessary force for the valve travel to address Stiction issues within the
valve.
2. Check the air pressure is within the specified range.
3. Check the torque of the valve packing gland & inspect it.
4. Inspect the valve’s internal portion for signs of scale, scarring, wear &
tear, and replace it if required.
5. Investigate the gasket seating surface on the valve bonnet
6. Check for any fouling on the valve stem plug and seat assembly.
7. If you are confused about fouling, replace it with a new one.
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24/02/2024, 23:48 How to Do Maintenance of Control Valve Which is Stuck in Field?

Inst Tools Menu

How to Do Maintenance of Control

is stuck in the field at a fixed position, and its detailed procedure.

2. Maintenance of Control Valve

3. Control Valve Inspection

5. Critical Components of Control Valve

6. How to Repair a Control Valve having a Stiction issue?

Hand tools such as spanner & Screw Diver

Handheld configurable HART communicator if positioner is smart.

Loop calibrator or multipurpose calibrator to feed 4 to 20 mA signal

Standard fittings with tubing to check actuator movement

Maintenance of Control Valve

If Valve not operating properly follow the below points

1. Inspect the control valve along with its associated accessories.

3. Apply constant air supply to the control valve.

13. If there is no current signal available, check cable connections by

equal rating as per design.

18. Change the configuration or feedback setting if feedback is not available

even after a healthy valve stroke is confirmed by the system command.

and another one is analog feedback from 0% to 100% which depends

upon valve design.

control system permissive conditions.

23. Calibration of a valve addresses if any problems occurred within the

control valve stroke.

in mA in an electro-pneumatic positioner or I-P converter.

of the same specification.

valve, vent port, and solenoid valve for subsequent addition.

30. Replace respective components if any significant problems were

accordingly with reference to calibration instructions, since the

calibration procedure of each model varies whit is not the same.

and test control valve movement by supplying external air to the

40. Perform manual valve operation to relieve the stuck state.

function to determine the point of the issue.

comes with air-passing ports to check the deterioration in the

43. If the actuator is experiencing passing problems conduct an overhaul on

spring, and other components within the control valve actuator.

Control Valve Inspection

2. Moving components such as cam, lever, spring, etc.

3. Diaphragm pressure Gauges

5. Nozzle & its Flapper.

6. Supply air leakage.

Why does a control valve get stuck, if the control

2. Basically, stiction means the combination of the words “stick” and

3. This condition allows the valve to retain in a constant position, without

4. When a Stiction problem in a valve occurs the valve movement needs

band set-point, which makes the valve stacked in a new or incorrect

wave pattern in process variables, resulting in process disruption and

Critical Components of Control Valve

3. Trim elements such as Plug, Seat, Cage, and Stem.

4. Bonnet Gland Packing Box

5. Gasket Seating Surface

6. Body Wall NDT Test

7. Valve Positioner Condition

8. Valve body Stud Bolts and Nuts

10. Hand-Wheel (if installed)

11. Flange Gasket Surfaces

How to Repair a Control Valve having a Stiction

2. Check the air pressure is within the specified range.