Limit Switch Options
Feature Report
Advances in Valve
Position Monitoring
New control-valve technologies
improve performance
and lower costs
Jack DiFranco
Westlock Controls
D
emanding application require-
ments coupled with improved
downstream control devices
and enhanced instrument di-
agnostics have led to major changes
in process-valve monitoring and con-
trol. Factors driving these changes in
the chemical process industries (CPI)
include the need for lower plant op-
erating costs, reduced maintenance
requirements, greater efficiency and
reliability in onstream performance,
and increased safety.
The valve positioner is a critical
component of the control valve, which
is the final control element in a process
loop. Positioners convert electrical sig-
nals to pneumatic signals in order to
control actuator displacement. This ul-
timately keeps a valve at an interme-
diate position in response to a variable
process-control signal. Various indus-
tries utilize actuated-valve systems.
For example, in petrochemical plants,
actuated-valve systems control fluid
flow during process operations. They
are also a critical component of an
emergency shutdown system (ESD).
In these applications, it is desirable
to know the exact status of the valve
(open or closed) on a continuous basis.
In automated plants, position sen-
sors help monitor and control pro-
duction processes by confirming that
critical activities are completed as
intended. More specifically, their pri-
mary function is to detect the pres-
ence, or absence, of a moving object
or “target.”
Prior to the invention of the elec-
tronic distributed control system
46 Chemical Engineering www.che.com December 2007
46-50 CHE 12-07.indd 46
(DCS), valves using pneumatic actua-
tors would normally come with pneu-
matic positioners. The control signals
were typically 3–15 psig where 3 psig
would indicate fully closed and 15 psig
fully open. However, these signals
could be reversed, or the ranges could
be split at 3–9 psig or 9–15 psig, for
example, depending on the process
application. A 6–30 psig range has
also been used. As the demand for ef-
ficiency and quality continued to rise,
wind-up, deadband and hysteresis
were impediments to improving pro-
cess performance.
With the invention of the DCS, 4–
20-mA current loops were standard-
ized for industrial control applications.
Most positioners allowed users to de-
fine values and control-valve position-
ing in the 4–20-mA range — “open to
closed” or “closed to open”.
Recent advances
In the last few decades, there have
been significant changes in industrial
process valves. Developments such
as digital fieldbus protocols and low-
power CPUs hastened the evolution of
the valve positioner as a computer. Just
as process sensors and controllers have
acquired “smart” capabilities, valve po-
sitioners and controllers have followed
the same route. Among the major de-
velopments are improvements to intel-
ligence, switching and feedback.
Greater intelligence. A close look
at modern, digital valve positioners
(DVPs) will reveal onboard micropro-
cessors, embedded sensors, final de-
vice-feedback sensors, digital commu-
nications, advanced diagnostics and
specialized algorithms.
DVPs have the intelligence to sift
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through mountains of raw data to
find the useful information and send
it automatically to where it is needed.
Building this kind of intelligence into
field devices is crucial in order to reap
the full benefits of modern process-au-
tomation technology.
Improved switching. Today’s elec-
trical valve-position indicators are
mounted either directly on a valve
actuator or indirectly using non-con-
tact remote-feedback devices. They
are used with both rotary-actuated
valves and linear-actuated valves and
provide two basic switching options:
non-contact and mechanical.
Non-contact switches or proximity
sensors, enunciate position in the pres-
ence or absence of a target. They can be
either magnetic, such as in the case of
reed switches and Hall-effect sensors,
or metal (ferrous or non-ferrous) for in-
ductive or time-to-limit (TTL) sensors.
Mechanical switches are activated by
energized arms connected to a moving
stem or shaft (Figure 1).
Expanded feedback. Some valve-po-
sition indicators provide visual feed-
back information on a rotating dial or
sliding scale. Other products feature a
light-emitting diode (LED) indicator
or both forms of position feedback. The
latest control monitors, in addition to
position feedback LEDs, include out-
put state LEDs providing visual indi-
cation of voltage to the solenoid. This
confirms power is being delivered by
the I/O card to the device and assists
in field diagnostics.
Valve position indicators with posi-
tion transmitters are also available.
These devices provide continuous, sig-
nal-based information about a valve’s
open, closed or intermediate position.
11/29/07 5:44:22 PM
 5BSHFU
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Performance challenges
A natural response to the increasing
economic, environmental and competi-
tive pressures facing process plants is
to modernize automation technology.
Many companies are investing in pow-
erful, state-of-the-art control instru-
mentation as a result. Unfortunately,
these efforts often suffer from the per-
formance of the final control element.
The precise monitoring and control of
valve position is essential for efficient
automation of both discrete and con-
tinuous production processes.
Despite progress in switch technol-
ogy for valve positioners, including
improvements in mechanical, limit-
switch and reed-switch designs (for
this and other definitions, see box,
p.50), new ways to address valve per-
formance and reliability issues are
still sought. Common problems in-
clude mechanical wear, environmental
hazards, human error and inaccuracy.
Mechanical wear. Most valve po-
sitioners utilize some type of rotary
potentiometer for converting linear to
rotary feedback. These devices include
mechanical linkages subject to wear
over time, not to mention degradation
in performance. The rotary potentiom-
eter is very similar to a variable resis-
tor. It has a coil of wire shaped in an
arc with a wiper, which moves across
the wire coil. As the wiper, which is at-
tached to the valve cam shaft, moves
across the coil of wire, a differing volt-
age is output proportional to the angle
at which the wiper is located.
Non-contact technology was devel-
oped to minimize costs by reducing ser-
vice and repair requirements over the
life of the positioner. The non-contact
design eliminates mechanical moving
46-50 CHE 12-07.indd 47
Figure 1. Mechanical
switches require a physi-
cal connection between the
switch and the trigger as-
sembly. Proximity switches
are indirectly coupled to the
trigger assembly through the
interaction of the switching
element and either a magnetic
field or appropriately interac-
tive material
components between the
actuator and the positioner. Instead, it
employs a Hall-effect sensor that picks
up a magnetic field and relays the posi-
tion of the valve and the actuator back
to an integrated microprocessor. This
approach eliminates hysteresis due to
mechanical wear, allowing hard cal-
culations to be achieved based in the
analog-to-digital (A/D) converter from
the Hall-effect sensor to the processor.
Another key benefit of non-contact
positioning technology is improved
linearity on large stroke calculations.
These devices offer more accurate lin-
earity figures than converting linear
travel to quarter turn with mechani-
cal linkages. While the Gauss field
of a magnet may degrade over time,
a simple auto calibration can correct
any feedback errors quickly and eas-
ily, as opposed to changing the entire
linkage or potentiometer to achieve
the same result.
Environmental hazards. Corrosion
resistance is a major consideration for
valve positioning and control equip-
ment in low-voltage industrial appli-
cations. Humidity, hazardous chemi-
cals and gases, as well as dirt and
debris, all decrease the reliability and
life expectancy of a switching device.
Mechanical-limit switches have
little protection against moisture,
dust and corrosion, and with exposed
contacts they are not suited for use in
hazardous areas without special gold-
plated contacts and field intrinsically
safe (IS) barriers and/or an explosion-
proof housing. Plus, as mechanical
devices, they rely on multiple moving
parts that make them subject to pre-
mature wear and failure.
The reliability of reed switches suf-
fered following the automation indus-
Chemical Engineering www.che.com December 2007
try’s adoption of digital technology.
Even reed switches with tungsten ele-
ments can fail when using low currents
(I < 10 mA) for discrete I/O. Tungsten
oxide buildup can increase the resis-
tance and sticking of the reed-switch
elements to the point where the host
system can no longer accurately de-
termine whether the switch is open
or closed. As a result, the operator re-
ceives an erroneous “open” valve posi-
tion reading at all times.
Reed switches are also prone to fail-
ure in high voltage (120 V a.c.) appli-
cations using digital I/O (capacitance
> .01 microFarads) where the I/O card
does not have appropriate resistors or
field resistors are not installed to pro-
tect against capacitive discharge.
Resistors must be properly sized for
the application, regardless of whether
they include conventional, tungsten or
rhodium elements. The switches have
the potential to arc and weld shut if
the capacitor discharges at a certain
time between opening and closing cy-
cles. Sizing resistors and maintaining
service on these devices is no longer
viable with new technology such as
bifurcated reed switches or the use of
transmitters for position sensing.
Human error. For many end users,
adjusting electro-mechanical switch
settings for a given valve application
is no easy task. This is because the
characteristics of valve design and
operation vary greatly between high-
performance valves, such as metal-
seated butterfly valves and standard
ball valves.
Calibration adjustments made by
field technicians tend to vary with
each type of valve, and may not take
the unique dynamics of different de-
vices into account. Limit switches
always require adjustment during
installation and are actuated by an
adjustable cam, prone to needing re-
adjustment during its service life.
Human error caused by a lack of
consistency in calibrating mechani-
cal-limit switches to valve position
can create hysteresis values greater
or less than optimum, which in turn,
result in false alarms, unnecessary
repairs, and frequent downtime.
Inaccurate readings. Another
problem with conventional valve po-
sitioners is the potential for false or
47
11/29/07 5:44:45 PM
 Feature Report
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inaccurate position feedback. Minor
fluctuations in actuator pressure,
seat wear inside the valve, or external
stresses on the switch package can
cause misalignment between a signal
trigger and a sensor or switch. This
misalignment can mean the operator
gets a false position reading. Inaccu-
rate position measurements carry the
potential for nuisance trip alarms or,
in critical service valves, a possible
process shutdown.
For example, due to thermal changes
in the process, a ball valve will not
necessarily go into the fully closed po-
sition. The limit switch may only close
the valve to within 0.5%, which is
still sufficient for proper seating and
sealing leaks. However, this condition
could trigger an alarm indicating the
valve is in an indeterminate position.
The operator has no way of confirm-
ing whether the valve is open or closed
other than the reading from the limit
switch. As a result, a technician must
go into the field to make a minor ad-
justment to the switch setting. While
this is a minor problem in a typical
plant setting, it can be a costly situ-
ation if the valve is located on an un-
manned, offshore platform, a remote
pipeline, or another inaccessible area.
In another case, a technician might
be called upon to adjust a high-per-
formance valve operating in high-
pressure steam service to eliminate
frequent spurious alarms. The tech-
nician increases the deadband on the
limit switch to, perhaps, an innocuous
2%. To the operator, the valve appears
fully closed when it really is not. A
48




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46-50 CHE 12-07.indd 48
FIGURE 3.
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small leak path is created and the es-
caping high-pressure steam destroys
the valve seat, resulting in costly re-
pairs and possible process downtime.
Latest technology
Because of their inherent performance
and reliability issues, mechanical
switches, reed switches, and solid-
state sensors cannot optimize valve
performance in critical service ap-
plications where timely response to
valve/actuator failure is essential. As
such, a new generation of devices that
change the way valves are monitored
and controlled has been developed.
Digital control transmitters. Intel-
ligent control transmitters are versa-
tile devices meeting a wide range of
valve monitoring and control require-
ments. Digital position transmitters
can handle virtually every control,
monitoring, and remote application in
an operating plant (Figure 2), includ-
ing simple on/off functions, rotary or
linear actuation, hazardous or non-
hazardous service, or an ESD system
with partial stroke testing.
Control transmitters, utilizing ad-
vanced, microprocessor-based intel-
ligence, provide reliable, consistent
feedback on process valves over their
full range. These transmitters elevate
valve-control performance by elimi-
nating position blind spots during the
stroke of a valve. They also eliminate
many troublesome nuisance alarms —
a key advantage for applications with
high maintenance costs at remote op-
erations or unmanned facilities.
With the control transmitter, posi-
tion sensing is performed by non-con-
tact means via an integrated Hall-
effect sensor and magnet assembly
detecting the presence, absence or
orientation of a magnetic trigger. The
sensor, powered by a constant current,
develops a varying electrical potential
proportional to the flux density of a
magnetic field applied perpendicularly
to the axis of the sensor (Figure 3).
Hall-effect sensors used for valve
positioning offer enhanced reliability
in extreme environments. The sensor
eliminates all mechanical contact be-
tween the actuator and the transmitter.
As there are no moving parts involved
within the sensor or magnet, typical life
expectancy is improved compared to
traditional electromechanical switches.
Additionally, the sensor and magnet
may be encapsulated in an appropriate
protective material, thus shielding it
from the environment.
Digital control transmitters supply
HART-enabled 4–20-mA continuous
position feedback. These transmitters
incorporate a low-power solenoid that
reduces the power levels for actuation
control to 5% of the energy required for
operation of conventional solenoids.
Due to their measurement preci-
sion, control transmitters allow the
true open and closed positions for
each category of valve to be deter-
mined. This accurate measurement
of valve position provides the data
required for the use of advanced con-
trol strategies and predictive mainte-
nance algorithms. The achieved ben-
efit in an ESD application is that the
solenoid is fully exercised in every
11/29/07 5:45:29 PM
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PST (partial stroke test) execution,
as opposed to venting the actuator
using positioners that have lower
CV, which is a value that indicates
relative flow capacity of a valve, and
higher maintenance.
Intelligent ‘non-contact’ proxim-
ity positioners. Intelligent proximity
positioners have refined the method-
ology for obtaining non-contact valve-
position feedback. Unlike traditional
positioners, they provide accurate
valve-position data without the need
for linkages or levers. Position sensing
is performed through the use of a non-
contact, solid-state Hall-effect proxim-
ity sensor (Figure 4).
Non-contact positioners eliminate
variance caused by mechanical po-
sition-feedback components by em-
ploying a servomechanism and 10-
bit A/D converter for the Hall-effect
voltage output.
At the heart of the digital proxim-
ity sensor is an analog proportional-
integral-derivative (PID) control
algorithm incorporating the Ziegler-
Nichols (Z-N) tuning procedure. The
time-honored “Z-N rule,” as intro-
duced in the 1940s, is a two-step tun-
ing approach that includes a test for
quantifying process behavior in terms
of how fast and how much the process
variable changes when the control ef-
fort changes. It also includes a set of
empirical formulas for translating
results of those tests into appropri-
ate performance settings or tuning
parameters for the controller, giving
engineers a practical and systematic
way of tuning PID loops (Figure 5).
46-50 CHE 12-07.indd 49
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Employing the Z-N Rule, the posi-
tion feedback-control algorithm takes
the integral and derivative values
out of the equation and continually
increases the proportional gain until
the system goes into unrecoverable os-
cillation. This maximizes the amount
of proportional gain allowed with any
device. Next, derivative and integral
values are introduced to achieve an
optimal PID constant, and the best
possible control performance.
The non-contact proximity posi-
tioner incorporates a true analog PID
algorithm updated in the form of a
digital device. The control algorithm
can typically accommodate a stepping
or ramping application. PID integers
can be adjusted to a constant indepen-
dently, based on a scale to achieve op-
timal performance.
Another advantage of intelligent,
low-bleed proximity positioners is that
they use less air than older electro-
pneumatic positioners (E/Ps). The low-
bleed design still allows some flow, en-
suring better sensitivity and accuracy
than “no bleed positioners.” Coupled
with PID control that precisely posi-
tions and holds to a setpoint, the low-
bleed positioner provides significant
cost savings by lowering instrument
air consumption.
Using a new intelligent positioner
can be more economical than using
older E/P technology. As an example,
the following shows estimated savings
in utility costs for air consumption,
where it is estimated that air costs
$0.25 per 1,000 ft3:
• Older E/P technology: 0.71 ft3/min X





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49
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60 min/h X $.25/1,000 ft3 X 8,760 h/yr
= $93.29/yr
• Non-contact intelligent positioner:
0.008 ft3/min X 60 min/h X $0.25/1,000
ft3 X 8,760 h/yr = $1.05/yr
Non-contact position feedback is ide-
ally suited for a host of control appli-
cations; since valve position sensing is
performed totally by proximity means,
hysteresis within the positioner is
non-existent. This capability allows
for extremely accurate tracking of the
control signal to within 0.10 mA. Some
control loops achieve changes in posi-
tioning to 0.03 mA
For linear control, the non-contact
proximity positioner represents a sig-
nificant departure from previous at-
tempts to reliably measure valve stem
position. With this device, a static
slide-by actuation assembly, attached
to the valve stem, is the only moving
part of the positioner. A microproces-
sor implements any alternation re-
quired to provide the equivalent of
equal percentage, quick opening, or
linear valve characteristics.
Since valve-position feedback is ac-
complished by non-contacting means,
proximity positioners have the unique
ability to be mounted remotely (up to
a distance of 50 ft as a standard and
up to 100 ft and even farther in some
special applications) from the device
they are controlling. In the event the
control valve is located in a high-vibra-
tion, high or low temperature, corrosive
or other environment that is hazardous
to plant personnel, the positioner elec-
tronics enclosure may be situated in a
neutral location with only the Hall-ef-
11/29/07 5:45:56 PM
 The Hall Effect and other terms
When discussing positioners, several terms are commonly used. The Hall effect refers to
the potential difference (Hall voltage) on opposite sides of an electrical conductor through
Feature Report which an electric current is flowing, created by a magnetic field applied perpendicularly
to the current.
A reed switch is an electrical switch operated by an applied magnetic field. It consists
of a pair of contacts on ferrous metal reeds in a hermetically sealed glass envelope. The
contacts may be normally open, closing when a magnetic field is present; or normally
closed and opening when a magnetic field is applied.
Bifurcated reed switches address the shortcomings of conventional reed switches in ap-
plications where ultralow power or capacitive discharge considerations apply. Bifurcated
switches incorporate a two-pronged switch design creating a self-cleaning “snap action”
movement that prevents contact oxide buildup and breaks non-resistive loads. This allows
for a universal application of the switches in low current and high-voltage digital I/O.❏

Figure 6. For hazardous area applica-
tions, the positioner-electronics enclo-
sure may be situated in a neutral location
with only the Hall-effect-sensor, remote
assembly mounted on the valve
fect sensor’s remote assembly mounted
on the valve (Figure 6).
Intelligent proximity positioners
also incorporate powerful diagnostics
helping plant operating personnel gain
a realtime perspective on the state of
control at the valve, including a view
into operating integrity and emerg-
ing alarm conditions. Manufacturers
have designed the positioners with
a preventive maintenance and data
logging system, that in parallel with
4–20-mA loops or network communi-
cations (such as Foundation Fieldbus),
performs online diagnostics of control
valves with automatic recordkeeping
for documentation purposes.
Advanced intelligent positioners and
discrete controllers now offer pressure
profiling for increased diagnostics and
predictive maintenance. Using HART
protocol, diagnostics can be extracted
with handheld devices or physically con-
nected systems. Bluetooth technology is
already being used in some cases.
Benefits of the new technologies
The evolution of process-valve posi-
tioning, as evidenced by the develop-
ment of intelligent, non-contact control
transmitters and proximity position-
ers, is keeping pace with demands for
lower total cost of ownership, reduced
maintenance, higher reliability, and
increased process uptime. Specific
benefits include:
Greater flexibility. Unlike conven-
tional positioners, non-contact devices
utilizing Hall-effect sensors provide
feedback of valve position without
the need for linkages, levers, or ro-
tary and linear seals. This allows a
remote-sensor-head assembly to be
mounted a considerable distance from
the electronics enclosure. The results
are greater flexibility for control engi-
neers, greater reliability in severe duty
applications, and improved safety for
technicians performing maintenance
work in the field.
Improved reliability. The use of a
non-contact sensor and low-power
solenoid enables a higher SIL (safety
integrity level) rating than a conven-
tional valve positioner. SILs are a
measure of system performance: in low
demand mode, SIL is a proxy for prob-
ability of failure on demand (PFD); in
high demand/continuous mode, SIL is
a proxy for failure rate. The higher the
SIL number, the better the safety per-
formance and confidence in the field
device (for more on SILs, see Tolerable
Risk, CE, September 2007, pp. 69–74).
Fewer errors. Employing HART com-
munications, DVPs can read a remote
signal for functions, such as calibra-
tion, diagnostics and partial stroke
testing. The digital format eliminates
the need for potentiometers used in
analog positioners, removes the po-
tential for human error when making
calibration adjustments, and provides
a non-interacting zero and span con-
sistent to every type of valve.
In addition, a single digital calibra-
tion can be made for an entire popula-
tion of valves. This allows easy deter-
mination of what is open, and what is
closed for different styles of valves.
Lower costs. Non-contact positioning
devices have a low cost of ownership
thanks to precise positioning capabili-
ties that can be customized by valve
application, ease of calibration and
service, and rich diagnostics for pre-
dictive maintenance signatures.
Increased versatility. Non-contact
digital valve positioners and control-
lers have been designed to commu-
nicate via most standard industrial
protocols, including HART, Foundation
Fieldbus, AS-I, Modbus, DeviceNet and
Profibus. These devices combine the
cost savings and increased diagnostic
capabilities of networks with the ad-
vantages of improved position sensors.
Summary
For discrete applications, intelligent
non-contact control transmitters utiliz-
ing Hall-effect sensors eliminate the
need for rotary mechanical “conversion
kits” that often result in poor perfor-
mance due to inherent hysteresis and
dead band caused by wear. For con-
tinuous control, intelligent non-contact
positioners eliminate the maintenance
issues associated with rotary-type
mechanical devices. Non-contact sens-
ing also allows the positioner to be
mounted remotely from the device it
is controlling — a huge advantage in
many process areas, which may be haz-
ardous or unapproachable.
Additionally, slow speed and pres-
sure-profile graphing available on in-
telligent-valve control devices enable
continuous monitoring of valve/actua-
tor performance in on/off applications.
The end result is improved onstream
process performance. ■
Edited by Dorothy Lozowski
Acknowledgements
The author would like to recognize
Herb Tucker, sales support manager
with Westlock Controls, for his contri-
bution in providing all graphics and
related technical input for this article.
Author
Jack DiFranco, Jr. is vice
president of sales for West-
lock Controls (280 Midland
Avenue, Saddle Brook, N.J.
07663; Email: jackdifranco@
westlockcontrols.com). He
has 22 years of industrial
field application and sales
experience. DiFranco holds a
B.S. degree in Software Engi-
neering from Colorado Tech-
nical University and carries
many certifications in his related technical
field. During his 13-yr tenure with Westlock,
Jack has provided field engineering support as
an applications engineer with specific emphasis
in field controls from a discrete and control per-
spective. This has included the proper selection
of switching elements for digital and conven-
tional I/O applications to tuning PID loops for
smart controls.

50 Chemical Engineering www.che.com December 2007

46-50 CHE 12-07.indd 50 11/29/07 5:46:30 PM