Control Valve Handbook | Chapter 4: Control Valve Accessories
Today, modern control systems use
electronic signaling to command the
control valve to open, close, or throttle.
Additionally, these systems use position
feedback signals and diagnostic
information to validate the operation
of the control valve. Furthermore, the
performance expectations of control
valves in terms of speed of response,
accuracy, stability, reliability, and safety
vary based on the process control needs.
Because control valves are installed in
many different and unique applications,
control valve accessories are necessary.
Accessories are the broad category of
instruments that are directly connected
to a control valve assembly.
There are five basic reasons that
instrumentation and accessories are
added to a control valve:
 Improve process control
 Improve safety for the process or
personnel
 Improve valve performance or speed
of response
 Monitor or verify the valve
responsiveness
 Diagnose potential valve issues
4.1 Environmental &
Application Considerations
Industrial plants, factories, mines, and
mills experience tough environmental
conditions due to their geographical
location and the processes involved
in manufacturing their products. As a
result, valves and instruments in these
facilities must be rugged and reliable.
Ambient temperatures for
instrumentation can range from -60
to 125°C (-76 to 257°F). Corrosive
atmospheres, such as salt water and
chemical exposure, may require
stainless steel or engineered resin
materials of construction. Intense
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vibration may require sturdy instrument
mounting, rugged internal mechanisms,
or remote mounting capability.
High levels of humidity can lead to
corrosion, so protection of electronic
components may be necessary.
Hazardous locations containing gaseous
or dusty atmospheres may require
instrumentation that is designed using
protection concepts, such as flameproof,
explosion proof, intrinsic safety, or
non-incendive. These environmental
and application conditions should be
considered when selecting the proper
control valve accessories. 
4.2 Positioners
A common control valve accessory is
the valve position controller, also called
a positioner. 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. A positioner requires position
feedback from the valve stem or shaft
and delivers pneumatic pressure to the
actuator to open and close the valve.
The positioner must be mounted on or
near the control valve assembly. There
are three main categories of positioners,
depending on the type of control signal,
the diagnostic capability, and the
communication protocol.
4.2.1 Pneumatic Positioners
The first category of positioners
are pneumatic positioners. Legacy
processing units may use pneumatic
pressure signaling as the control set
point to the control valves. Pressure is
typically modulated between 20.7 to
103 kPa (3 to 15 psig) to move the valve
from 0 to 100% position.
In a common pneumatic positioner
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Control Valve Handbook | Chapter 4: Control Valve Accessories
Supply
Beam
Figure 4.1 Typical Pneumatic, Single-Acting Positioner Design
design (Figure 4.1), the position of the
valve stem or shaft is compared with the
position of a bellows that receives the
pneumatic control signal. When the
input signal increases, the bellows
expands and moves a beam. The beam
pivots about an input axis, which moves
a flapper closer to the nozzle. The nozzle
pressure increases, which increases the
output pressure to the actuator through
a pneumatic amplifier relay. The
increased output pressure to the
actuator causes the valve stem to move.
Stem movement is fed back to the beam
by means of a cam. As the cam rotates,
the beam pivots about the feedback axis
to move the flapper slightly away from
the nozzle. The nozzle pressure
decreases and reduces the output
pressure to the actuator. Stem
movement continues, backing the
flapper away from the nozzle until
equilibrium is reached.
When the input signal decreases, the
bellows contracts (aided by an internal
range spring) and the beam pivots
76
Output to
Diaphragm
Relay
Instrument
Bellows
Feedback Axis
Pivot
Nozzle
Flapper Assembly
Direct Action
Quadrant
Input Axis
Cam
Reverse Action
Quadrant
about the input axis to move the flapper
away from the nozzle. Nozzle pressure
decreases and the relay permits the
release of diaphragm casing pressure
to the atmosphere, which allows the
actuator stem to move upward. Through
the cam, stem movement is fed back
to the beam to reposition the flapper
closer to the nozzle. When equilibrium
conditions are obtained, stem movement
stops and the flapper is positioned to
prevent any further decrease in actuator
pressure. See Figure 4.1.
4.2.2 Analog I/P Positioners
The second type of positioner is an
analog I/P positioner. Most modern
processing units use a 4 to 20 mA DC
signal to modulate the control valves.
This introduces electronics into the
positioner design and requires that the
positioner convert the electronic current
signal into a pneumatic pressure signal
(current-to-pneumatic or I/P).
In a typical analog I/P positioner (see
Figure 4.2), the converter receives a DC
 Control Valve Handbook | Chapter 4: Control Valve Accessories

input signal and provides a proportional increasing control signal, one output
pneumatic output signal through pressure always increases and the other
a nozzle/flapper arrangement. The output pressure decreases.
pneumatic output signal provides the
input signal to the pneumatic positioner.
Otherwise, the design is the same as the
pneumatic positioner.

-
4-20 mA +
Input Signal

Pneumatic Signal
from Converter
Bellows
Converter

Feedback Axis
Supply
Output to Nozzle
Actuator
Beam
Relay
Direct-Acting
Quadrant
Rotary
Shaft Arm
Input Axis

Cam
Pivot
Reverse-Acting
Flapper Assembly Quadrant

Figure 4.2 Typical Single-Acting Analog I/P

Positioner Design
Figure 4.3 Digital Valve Controller Mounted on a
Control Valve
4.2.3 Digital Valve Controllers
Double-acting actuators use both
While pneumatic positioners and analog
outputs, whereas single-acting actuators
I/P positioners provide basic valve
use only one output. The changing
position control, digital valve controllers
output pressure causes the actuator
add another dimension to positioner
stem or shaft to move. Valve position
capabilities. This type of positioner is a
is fed back to the microprocessor.
microprocessor-based instrument. The
The stem continues to move until the
microprocessor enables diagnostics and
correct position is attained. At this
two-way communication to simplify
point, the microprocessor stabilizes the
setup and troubleshooting.
drive signal to the I/P converter until
In a typical digital valve controller, equilibrium is obtained.
the control signal is read by the
In addition to the function of controlling
microprocessor, processed by a digital
the position of the valve, a digital
algorithm, and converted into a drive
valve controller has two additional
current signal to the I/P converter.
capabilities: diagnostics and two-way
The microprocessor performs the
digital communication.
position control algorithm rather
than a mechanical beam, cam, and 4.2.3.1 Diagnostics
flapper assembly. As the control signal
increases, the drive signal to the I/P The microprocessor inside the digital
converter increases, increasing the valve controller allows the positioner to
output pressure from the I/P converter. run, analyze, and store diagnostic tests.
This pressure is routed to a pneumatic Diagnostic information is useful in
amplifier relay and provides two determining the health of the entire
output pressures to the actuator. With control valve assembly. Through the

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Control Valve Handbook | Chapter 4: Control Valve Accessories

use of pressure sensors, temperature information between the control

sensors, travel sensors, and internal system and the digital valve controller.
readings, graphical representations of For positioners outfitted with wireless
control valve performance and health are capability, digital information can be
created and recommended actions are transmitted independent of the control
presented. This information is then used system wiring. 
to identify elements of the control valve
assembly that may require maintenance.
4.3 I/P Transducers
4.2.3.2 Two-Way Digital
Communication In some applications, the high level of
postioning accuracy that a positioner
The microprocessor inside the digital provides is not required. In these
valve controller also allows the applications, an electro-pneumatic (I/P)
positioner to communicate with the transducer can be used. An I/P transducer
control system via a digital signal. This (Figure 4.4) uses a converter module that
enables the digital valve controller to converts a 4 to 20 mA current input to a
provide additional feedback, such as proportional pressure output. An internal
actual valve travel and diagnostic alerts pneumatic amplifier relay provides the
back to the control system. capacity necessary to deliver output
One widely used protocol is HART® pressure to the control valve actuator.
communication. HART communication There is no valve position feedback and
uses a digital signal superimposed over responsiveness is very quick. 
the traditional 4 to 20 mA DC control
signal. This communication protocol
allows the host system to be used
to configure, calibrate, and monitor
the health of the positioner. HART
communication offers the benefits
of digital communication with the
familiarity of a 4 to 20 mA control system.
FOUNDATION™ fieldbus is another
industry standard protocol. This protocol
is all digital, which means that the
control signal (set point) is digital, rather
than a 4 to 20 mA DC current. Similar to
HART communication, the host system
can also be used to configure, calibrate,
and monitor the positioner.
PROFIBUS is also a common industry
protocol that provides all digital Figure 4.4 Transducer Mounted on a Control Valve
communication. The physical layer
for PROFIBUS and FOUNDATION
fieldbus is the same; however, the 4.4 Volume Boosters
communication protocols differ and Positioners and I/P transducers are
offer their own advantages. designed to provide enough pneumatic
Wireless technology offers an output capacity to drive a typical
additional method to communicate throttling control valve. However, some

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 Control Valve Handbook | Chapter 4: Control Valve Accessories

applications require faster stroking
speeds. When the actuator volume is
large, the positioning speed of response
can become more of a concern.
Volume boosters are used to provide
additional pneumatic output capacity
to a valve assembly (Figure 4.5). A
large, sudden change in input signal
(output pressure from the positioner)
causes a pressure differential to exist
between the input signal and the
output of the booster. When this
occurs, the diaphragms move to open
the supply port or the exhaust port,
whichever action is required to reduce
the differential. The port remains open
until the difference between the booster
input and output pressure is within the
deadband limit of the booster.
With the bypass restriction adjusted

Signal Input
Diaphragms Bypass Restriction
Adjusting Screw

Bypass Restriction

Exhaust

Exhaust Port

Supply Supply Port

Output to Actuator

Figure 4.5 Volume Booster Sectional View

Volume
Booster
Pipe Tee
Pipe Bushing
Body
Body Pipe Nipple
Protector

Positioner
Optional Output
Diagnostic
Connection

Signal

Positioner Supply
Actuator Pressure
Regulator

Figure 4.6 Typical Booster Installation with a Single-Acting Actuator

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Control Valve Handbook | Chapter 4: Control Valve Accessories
for stable operation, signals having
small magnitude and rate changes
pass through the bypass restriction
and into the actuator without initiating
booster operation. Both the supply and
exhaust ports remain closed, preventing
unnecessary air consumption and
possible saturation of positioner relays.
Single-acting actuators typically use
one volume booster (Figure 4.6).
Double-acting actuators require at
least two volume boosters, one to feed
each side of the actuator piston. Some
applications, such as compressor anti-
surge or turbine bypass, may require
additional volume boosters to provide
the needed pneumatic volume for fast
valve response. 
4.5 Safety Instrumented
Systems (SIS)
The primary purpose of a control valve
is to modulate the flow of liquid or
gas in a pipe within a process control
loop. Within these same process loops,
there are also emergency vent, block,
or isolation valves. These valves are
Figure 4.7 SIS Digital Valve Controller on a Safety Valve
80
typically on/off valves that are used
to take the process loop to a safe
state in the event of a process control
emergency (Figure 4.7). A separate
safety system, often controlled by a
logic solver, controls these valves.
4.5.1 Partial Stroke Testing
Because safety valves are static and do
not modulate under normal conditions,
they are prone to sticking. When an
emergency demand occurs, there is a
risk that the valves will not move when
commanded. To mitigate this risk, the
digital valve controller can be used as a
partial stroke testing device.
An important function of the instrument
is periodically exercising the valve. This is
performed with a valve partial stroke test
(PST). The PST slowly moves the valve
a portion of the total valve travel and
then returns to the normal state. This
exercises the mechanical components of
the safety valve with minimal disruption
to the process loop. Furthermore,
the digital valve controller has the
ability to diagnose potential issues and
communicate any alerts if the test fails.
 Control Valve Handbook | Chapter 4: Control Valve Accessories

4.5.2 Safety Function and liquid displacement lever assembly, or

Product Certification temperature bulb.

A spring-return, single-acting actuator

provides an inherent fail mode for the
valve assembly. During an emergency
demand, the typical method to move the
valve to the safe state is to remove the
air pressure to the actuator and allow the
spring to position the valve. A solenoid
valve and/or digital valve controller can
be used to perform this function. There
may be additional instrumentation
on the safety valve, such as boosters,
position transmitters, and trip systems.
All of these elements must be evaluated
for their effect on the safety system.
These elements can fail by causing
an unplanned trip or by not getting
the safety valve to the safe state. The
Failure Modes, Effects, and Diagnostics
Analysis (FMEDA) provides metrics
for each component. This allows a
safety engineer to design the safety
Figure 4.8 Pneumatic Controller on a Control Valve
instrumented system to the desired
level of risk reduction. See Chapter The input element is connected to the
12 for more information about safety process pointer (set point adjustment)
instrumented systems.  and to the flapper by connecting links.
As the process input increases (in a
direct-acting controller), the flapper
4.6 Controllers moves toward the nozzle, which restricts
In some applications, control of the flow through the nozzle and increases
process is performed locally without nozzle pressure. When this occurs, relay
the need for a large scale distributed action increases the output pressure to
control system (DCS) or programmable the actuator, which modulates the
logic controller (PLC). Local controllers control valve. Output pressure is fed
are used to measure process conditions, back to the proportional bellows. The
such as pressure, temperature, or level action of the proportional bellows
and directly drive the pneumatic output counters the flapper movement that
pressure to a control valve (Figure 4.8). resulted from the process input change.
It then moves the flapper away from the
The input to the local controller is nozzle until the controller reaches a
typically pressure, differential pressure, point of equilibrium. The set point
temperature, or level displacement. adjustment changes the proximity of the
The process measurement is translated nozzle and flapper, as does a change in
into a beam-flapper assembly process input. However, when the set
movement, which is connected to an point is changed, the nozzle moves with
input element. The input element can respect to the flapper.
be a Bourdon tube, bellows assembly,

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Control Valve Handbook | Chapter 4: Control Valve Accessories
The proportional band adjustment
knob positions the nozzle on the flapper.
Increasing or widening the proportional
band moves the nozzle to a position on
the flapper where less flapper motion
occurs, decreasing the gain of the
controller. Decreasing or narrowing the
proportional band moves the nozzle
toward a position where more flapper
motion occurs, increasing the gain.
Controller action is changed from direct
to reverse by turning the proportional
band adjustment knob to position the
nozzle to a point on the flapper where
the direction of the flapper motion
versus the input motion is reversed.
With the controller in the reverse-acting
mode, an increase in process input
causes a decrease in output pressure
to the actuator. Supply pressure bleeds
through a fixed orifice in the relay and
exits through the nozzle. The nozzle
pressure registers on the large relay
diaphragm and modulates loading
pressure on the small relay diaphragm.
This also modulates the controller output
pressure to the actuator (Figure 4.9).
Controllers with proportional-plus-
reset operation are similar to that of
proportional-only controllers, except that
output pressure is fed back to the reset
Manual Set Point
Adjustment Proportional
Bellows
Process Pointer
Remote Set Point
Connected Here
Input Element
Connected Here
Connecting
Link
Beam
Flapper
Supply Pressure
Nozzle
Output Pressure
Nozzle Pressure
Reset Pressure
Proportional Pressure
Figure 4.9 Pneumatic Controller Schematic
82
and proportional bellows. In operation,
proportional-plus-reset controllers
minimize the offset between the process
variable and the set point.
Controllers with proportional-plus-reset-
plus-rate have a rate valve, an adjustable
restriction that briefly maintains
the controller gain to accelerate the
corrective action for slow systems
(Figure 4.10). The rate action delays the
gain reduction just long enough to allow
the system to respond to the change,
but not long enough for the system to
become unstable. Then, the low gain
provided by the proportional action
keeps the system stable. Finally, the reset
action slowly increases the gain and
returns the process toward the set point.
Anti-reset windup reduces overshoot
of the process input that can result
from large or prolonged deviation
from the set point. This option can be
adjusted to operate on either increasing
or decreasing output pressure. The
differential relief valve operates when the
difference between proportional bellows
pressure and reset bellows pressure
reaches a predetermined value. 
Reset Bellows (Vented) Reverse-Action Quadrant
Proportional
Band Adjustment Feedback
Link
Feedback
Motion Flapper
Pivot
Input
Direct-Action
Quadrant Motion
Output Pressure
to Final Control Element
Relay
Supply Pressure
Proportional-Only Control
 Control Valve Handbook | Chapter 4: Control Valve Accessories

To Reset
Bellows To Nozzle
To Proporitional
Bellows
Output

Relay

Supply Pressure Differential Supply Pressure

Output Pressure Relief Valve Reset Valve

Nozzle Pressure Rate Valve

Reset Pressure
Proportional + Reset + Rate Control
Proportional Pressure
With Anti-Reset Windup

Figure 4.10 Pneumatic Controller Schematic

4.7 Position Transmitters 4.8 Limit Switches

The purpose of a position transmitter is
to provide independent valve position
feedback to the control system.
Position feedback is often used for
process monitoring, troubleshooting,
or startup/shutdown verification.
The position transmitter is mounted
directly to the valve and measures the
position of the valve stem or shaft.
In a wired installation, the position
transmitter provides a 4 to 20 mA signal
that corresponds with the throttling
range of the control valve. In a wireless
installation, the position transmitter
provides a 0 to 100% digital signal
(Figure 4.11). 
The purpose of a limit switch is to
provide a discrete open or close signal
to the control system when the valve
reaches a specific position within its
range of travel. Limit switches are
also used for process monitoring,
troubleshooting, or startup/shutdown
verification. The limit switch receives
position feedback from the valve stem
or shaft and will send either a wired
or a wireless signal to the control
system. There are many different
switch technologies available, such as
proximity, solid state, magnetic, and
contact closure. 

4.9 Solenoid Valves

A solenoid valve is installed in the
pneumatic tubing path to the actuator.
In some applications, the solenoid valve
will vent the air from the actuator to
allow the valve to move to its no air, fail
state. In other applications, the solenoid
valve will trap air in the actuator to
lock the valve in its current position.
Three-way solenoids are generally used
to operate spring-return actuators and
four-way solenoids are generally used for
Figure 4.11 Wireless Position Monitor Mounted on
double-acting actuators. The solenoid
an Actuator valve is activated by making or breaking

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Control Valve Handbook | Chapter 4: Control Valve Accessories
a discrete electrical signal from the
control system. See Chapter 11 for more
information about solenoid valves. 
4.10 Trip Systems
Trip systems are used in control
applications where a specific actuator
action is required in the event that supply
pressure is lost (Figure 4.12). These
are used with double-acting actuators
that do not have an inherent no air, fail
state or with single- or double-acting
actuators to provide pneumatic lock-up.
When supply pressure falls below the trip
point, the trip valve causes the actuator
to fail up, lock in the last position, or fail
down. For double-acting applications,
a volume tank provides the reserve
pneumatic air capacity to operate
the valve until the supply pressure is
restored. When the supply pressure
rises above the trip point, the trip valve
automatically resets, allowing the
Spring
Valve Plug
Upper Diaphragm
Exhaust Port
Supply Pressure
Lower Diaphragm
Port D
Port E
Lower
Ports
Port F
Supply Pressure
Control Pressure to Top of
Cylinder (Blocked)
Control Pressure to Bottom
of Cylinder (Blocked)
Figure 4.12 Trip Valve Shown in Tripped Condition
84
system to return to normal operation. 
4.11 Handwheels
Handwheels for diaphragm actuators
are often used as adjustable travel
stops. They also provide a ready means
of positioning the control valve in an
emergency.
Side-mounted handwheels can be used
to stroke the valve in either direction
at any point in the actuator stem
travel (Figure 4.13). The side-mounted
handwheel can be positioned to limit
travel in either direction, but not both
at the same time. With the handwheel
in the neutral position, automatic
operation is possible throughout full
valve travel. In any other position, valve
travel will be restricted.
Top-mounted handwheels are used for
infrequent service to manually stroke
the valve (Figure 4.14). 
Main
Spring Actuator
Vent
Control
Device
Port A
Port B
Upper Ports
Plug
Port C Assemblies
Volume
Tank
Pressure to Top of Cylinder
(from Volume Tank)
Pressure from Bottom of Cylinder
(Venting)
Lower Diaphragm Loading Pressure
(Being Vented)
 Control Valve Handbook | Chapter 4: Control Valve Accessories

Figure 4.13 Actuator with Side-Mounted Handwheel Figure 4.14 Actuator with Top-Mounted Handwheel

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