OSA

OSA Industries Phils. Inc.

Unit 4-113 North Main Ave. cor. Commerce Rd Laguna Technopark Inc., Binan, Laguna Philippines 4024 Tel.: (049) 541-1470 (049) 541-3101 Fax: (049) 541-1180

Industries

Control Valve (CV) Troubleshooting / Refurbishing Bench Testing / Calibration of Positioners Training Program

BRINGING QUALITY SERVICE FROM QUALITY-ORIENTED PEOPLE

TYPICAL LEVEL CONTROL LOOP

LOAD 4-20mA

Level Controller (LIC)

4-20mA

LT
Level Transmitter (LIT) Regulator Compressed Air Supply Storage Tank

Level Control Valve

1. Reciprocating 2. Rotary

OSA

OSA Industries Phils. Inc.

Unit 4-113 North Main Ave. cor. Commerce Rd Laguna Technopark Inc., Binan, Laguna Philippines 4024 Tel.: (049) 541-1470 (049) 541-3101 Fax: (049) 541-1180

Industries

Control Valve (CV) Troubleshooting / Refurbishing Bench Testing / Calibration of Positioners Training Program

Control Valve (CV) Repair and Reconditioning Capabilities Control Valve (CV) Repair for the Following Types: for the Types:

Globe

Butterfly

Ball

BRINGING QUALITY SERVICE FROM QUALITY-ORIENTED PEOPLE

Terminologies
Flow Direction

Flow to Close (Flow Over)

Flow to Open (Flow Under)

OSA

OSA Industries Phils. Inc.

Unit 4-113 North Main Ave. cor. Commerce Rd Laguna Technopark Inc., Binan, Laguna Philippines 4024 Tel.: (049) 541-1470 (049) 541-3101 Fax: (049) 541-1180

Industries

Control Valve (CV) Troubleshooting / Refurbishing Bench Testing / Calibration of Positioners Training Program

Common Types of Damages Common Types of Damages

Cavitation Flashing Erosion Chemical Corrosion Fretting

BRINGING QUALITY SERVICE FROM QUALITY-ORIENTED PEOPLE

OSA

OSA Industries Phils. Inc.

Unit 4-113 North Main Ave. cor. Commerce Rd Laguna Technopark Inc., Binan, Laguna Philippines 4024 Tel.: (049) 541-1470 (049) 541-3101 Fax: (049) 541-1180

Industries

Control Valve (CV) Troubleshooting / Refurbishing Bench Testing / Calibration of Positioners Training Program

Initial Steps Initial Record valve details stated on the nameplate Verification of initial problem reported regarding the valve Data Sheet Verification

BRINGING QUALITY SERVICE FROM QUALITY-ORIENTED PEOPLE

OSA

OSA Industries Phils. Inc.

Unit 4-113 North Main Ave. cor. Commerce Rd Laguna Technopark Inc., Binan, Laguna Philippines 4024 Tel.: (049) 541-1470 (049) 541-3101 Fax: (049) 541-1180

Industries

Control Valve (CV) Troubleshooting / Refurbishing Bench Testing / Calibration of Positioners Training Program

Initial Steps Initial Steps Record valve details stated on the nameplate Verification of initial problem reported regarding the valve

BRINGING QUALITY SERVICE FROM QUALITY-ORIENTED PEOPLE

OSA

OSA Industries Phils. Inc.

Unit 4-113 North Main Ave. cor. Commerce Rd Laguna Technopark Inc., Binan, Laguna Philippines 4024 Tel.: (049) 541-1470 (049) 541-3101 Fax: (049) 541-1180

Industries

Control Valve (CV) Troubleshooting / Refurbishing Bench Testing / Calibration of Positioners Training Program

Initial Steps Initial Steps Data Sheet Verification

BRINGING QUALITY SERVICE FROM QUALITY-ORIENTED PEOPLE

OSA

OSA Industries Phils. Inc.

Unit 4-113 North Main Ave. cor. Commerce Rd Laguna Technopark Inc., Binan, Laguna Philippines 4024 Tel.: (049) 541-1470 (049) 541-3101 Fax: (049) 541-1180

Industries

Control Valve (CV) Troubleshooting / Refurbishing Bench Testing / Calibration of Positioners Training Program

Typical Globe-Type Control Typical Globe-Type Control Valve Disassembly Valve Disassembly Marking procedure on external components for proper orientation.

BRINGING QUALITY SERVICE FROM QUALITY-ORIENTED PEOPLE

OSA

OSA Industries Phils. Inc.

Unit 4-113 North Main Ave. cor. Commerce Rd Laguna Technopark Inc., Binan, Laguna Philippines 4024 Tel.: (049) 541-1470 (049) 541-3101 Fax: (049) 541-1180

Industries

Control Valve (CV) Troubleshooting / Refurbishing Bench Testing / Calibration of Positioners Training Program

Overview of Typical Air-to-Open Actuator Overview of Typical Air-to-Open Actuator

Upper Diaphragm Case Diaphragm Plate Compressor Unit Spring Spacer Diaphragm O-Ring Actuator Stem Yoke Scale-Travel Pointer Stem Connector

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Actuator S/A

CONVENTIONAL FLAT DIAPHRAGM ACTUATOR

Limitations: Not field reversible from direct to reverse acting

CYLINDER OR PISTON ACTUATORS

Model 51 Nimco Without Spring Double acting Global Release

OSA

OSA Industries Phils. Inc.

Unit 4-113 North Main Ave. cor. Commerce Rd Laguna Technopark Inc., Binan, Laguna Philippines 4024 Tel.: (049) 541-1470 (049) 541-3101 Fax: (049) 541-1180

Industries

Control Valve (CV) Troubleshooting / Refurbishing Bench Testing / Calibration of Positioners Training Program

Control Valve Body S/A 21000 Control Valve Body S/A 21000
Plug Stem Packing Flange Packing Follower Packing Spacer Packing Valve Body Stud Nut Plug Pin Guide Bushing Cage Plug Valve Body Gasket Body Seat Ring Seat Ring Gasket

BRINGING QUALITY SERVICE FROM QUALITY-ORIENTED PEOPLE

OSA

OSA Industries Phils. Inc.

Unit 4-113 North Main Ave. cor. Commerce Rd Laguna Technopark Inc., Binan, Laguna Philippines 4024 Tel.: (049) 541-1470 (049) 541-3101 Fax: (049) 541-1180

Industries

Control Valve (CV) Troubleshooting / Refurbishing Bench Testing / Calibration of Positioners Training Program

Disassembly of Valve Disassembly of Valve Body Body Uncoupling of body from actuator. Removal of plug and seat.

BRINGING QUALITY SERVICE FROM QUALITY-ORIENTED PEOPLE

OSA

OSA Industries Phils. Inc.

Unit 4-113 North Main Ave. cor. Commerce Rd Laguna Technopark Inc., Binan, Laguna Philippines 4024 Tel.: (049) 541-1470 (049) 541-3101 Fax: (049) 541-1180

Industries

Control Valve (CV) Troubleshooting / Refurbishing Bench Testing / Calibration of Positioners Training Program

Typical Globe-Type Control Typical Globe-Type Control Valve Disassembly Valve Disassembly Removal of Positioner

Disassembly of Actuator

BRINGING QUALITY SERVICE FROM QUALITY-ORIENTED PEOPLE

OSA

OSA Industries Phils. Inc.

Unit 4-113 North Main Ave. cor. Commerce Rd Laguna Technopark Inc., Binan, Laguna Philippines 4024 Tel.: (049) 541-1470 (049) 541-3101 Fax: (049) 541-1180

Industries

Control Valve (CV) Troubleshooting / Refurbishing Bench Testing / Calibration of Positioners Training Program

Typical Globe-Type Control Typical Globe-Type Valve Disassembly Valve Removal of Internal Parts and Accessories of Actuator

BRINGING QUALITY SERVICE FROM QUALITY-ORIENTED PEOPLE

OSA

OSA Industries Phils. Inc.

Unit 4-113 North Main Ave. cor. Commerce Rd Laguna Technopark Inc., Binan, Laguna Philippines 4024 Tel.: (049) 541-1470 (049) 541-3101 Fax: (049) 541-1180

Industries

Control Valve (CV) Troubleshooting / Refurbishing Bench Testing / Calibration of Positioners Training Program

Exploded View of a Typical Globe-Type Control Exploded a Typical Globe-Type Control Valve Valve

BRINGING QUALITY SERVICE FROM QUALITY-ORIENTED PEOPLE

OSA

OSA Industries Phils. Inc.

Unit 4-113 North Main Ave. cor. Commerce Rd Laguna Technopark Inc., Binan, Laguna Philippines 4024 Tel.: (049) 541-1470 (049) 541-3101 Fax: (049) 541-1180

Industries

Control Valve (CV) Troubleshooting / Refurbishing Bench Testing / Calibration of Positioners Training Program

Control Valve Critical Parts Inspection Control Valve Inspection Actuator Diaphragm Actuator Shaft Trim Components (Plug, Seat, Cage and Stem) Packing Box on Bonnet Gasket Seating Surface NDT Test for Body Wall Valve Positioner Condition Body Stud Bolts and Nuts Actuator Spring Hand-Wheel (if any) Flange Gasket Surfaces
BRINGING QUALITY SERVICE FROM QUALITY-ORIENTED PEOPLE

OSA

OSA Industries Phils. Inc.

Unit 4-113 North Main Ave. cor. Commerce Rd Laguna Technopark Inc., Binan, Laguna Philippines 4024 Tel.: (049) 541-1470 (049) 541-3101 Fax: (049) 541-1180

Industries

Control Valve (CV) Troubleshooting / Refurbishing Bench Testing / Calibration of Positioners Training Program

Inspection Procedure Inspection Diaphragm Inspection

Inspection of Springs

BRINGING QUALITY SERVICE FROM QUALITY-ORIENTED PEOPLE

OSA

OSA Industries Phils. Inc.

Unit 4-113 North Main Ave. cor. Commerce Rd Laguna Technopark Inc., Binan, Laguna Philippines 4024 Tel.: (049) 541-1470 (049) 541-3101 Fax: (049) 541-1180

Industries

Control Valve (CV) Troubleshooting / Refurbishing Bench Testing / Calibration of Positioners Training Program

Inspection Procedure Inspection Procedure Wall thickness in wear areas (ANSI B16.34) Flange thickness (ANSI B16.5) Gasket Surfaces Guides

BRINGING QUALITY SERVICE FROM QUALITY-ORIENTED PEOPLE

OSA

OSA Industries Phils. Inc.

Unit 4-113 North Main Ave. cor. Commerce Rd Laguna Technopark Inc., Binan, Laguna Philippines 4024 Tel.: (049) 541-1470 (049) 541-3101 Fax: (049) 541-1180

Industries

Control Valve (CV) Troubleshooting / Refurbishing Bench Testing / Calibration of Positioners Training Program

Inspection Procedure Inspection Procedure Inspection of Gasket Seating Surface on Valve Bonnet

Inspection of Packing Box Wall

BRINGING QUALITY SERVICE FROM QUALITY-ORIENTED PEOPLE

OSA

OSA Industries Phils. Inc.

Unit 4-113 North Main Ave. cor. Commerce Rd Laguna Technopark Inc., Binan, Laguna Philippines 4024 Tel.: (049) 541-1470 (049) 541-3101 Fax: (049) 541-1180

Industries

Control Valve (CV) Troubleshooting / Refurbishing Bench Testing / Calibration of Positioners Training Program

Inspection Procedure Inspection Procedure Stem condition and Plug seating Contact inspection

Seat ring inspection for fouling

BRINGING QUALITY SERVICE FROM QUALITY-ORIENTED PEOPLE

OSA

OSA Industries Phils. Inc.

Unit 4-113 North Main Ave. cor. Commerce Rd Laguna Technopark Inc., Binan, Laguna Philippines 4024 Tel.: (049) 541-1470 (049) 541-3101 Fax: (049) 541-1180

Industries

Control Valve (CV) Troubleshooting / Refurbishing Bench Testing / Calibration of Positioners Training Program

Repair Job for Typical Butterfly-Type Control Valve Repair Job for Typical Butterfly-Type Control Valve
For butterfly-type control valves, the same inspection procedures apply for critical parts inspection. Inspection variation will only be on: Condition of Liner (Soft Seat), Condition of Disc, Condition of Shaft and Alignment

Actuator disassembly and inspection follows the same procedure as stated earlier

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OSA

OSA Industries Phils. Inc.

Unit 4-113 North Main Ave. cor. Commerce Rd Laguna Technopark Inc., Binan, Laguna Philippines 4024 Tel.: (049) 541-1470 (049) 541-3101 Fax: (049) 541-1180

Industries

Control Valve (CV) Troubleshooting / Refurbishing Bench Testing / Calibration of Positioners Training Program

Repair Job for Typical Ball -Type Control Valve Repair Job for Typical Ball -Type Control Valve
Repair and reconditioning of ball-type control valves follows standard procedures as stated earlier. Critical-part inspection is to be carried on: Actual ball condition(check for dents, pitting/abrasion) Valve seat/liner ( soft, metal ) For piston-type actuators: Supply air on actuator air-inlet Stroke actuator, exercise movement (extend & retract) Check possible air leakages on actuator body

BRINGING QUALITY SERVICE FROM QUALITY-ORIENTED PEOPLE

OSA

OSA Industries Phils. Inc.

Unit 4-113 North Main Ave. cor. Commerce Rd Laguna Technopark Inc., Binan, Laguna Philippines 4024 Tel.: (049) 541-1470 (049) 541-3101 Fax: (049) 541-1180

Industries

Control Valve (CV) Troubleshooting / Refurbishing Bench Testing / Calibration of Positioners Training Program

Valve Positioner Valve Positioner

Positioner calibration is always done whenever a control valve is overhauled. Procedures may vary with every model. Inspection of the following is necessary before doing any calibration work: moving parts (cam, lever, spring, etc..) o-rings diaphragm pressure gauges flapper and nozzle cracks air leaks from the: output, signal, & supply outlets

In cases of I/P positioners, electric coils and electronic cards must always be kept dry and free from moisture.
BRINGING QUALITY SERVICE FROM QUALITY-ORIENTED PEOPLE

OSA

OSA Industries Phils. Inc.

Unit 4-113 North Main Ave. cor. Commerce Rd Laguna Technopark Inc., Binan, Laguna Philippines 4024 Tel.: (049) 541-1470 (049) 541-3101 Fax: (049) 541-1180

Industries

Control Valve (CV) Troubleshooting / Refurbishing Bench Testing / Calibration of Positioners Training Program

Valve Reassembly Valve

Lapping of valve plug against seat Proper replacement of gaskets Application of anti-seize compound on bolts and nuts Proper replacement of packings (with proper emphasis on proper material to be used i.e, graphite, grafoil, teflon) and proper tightness

BRINGING QUALITY SERVICE FROM QUALITY-ORIENTED PEOPLE

OSA

OSA Industries Phils. Inc.

Unit 4-113 North Main Ave. cor. Commerce Rd Laguna Technopark Inc., Binan, Laguna Philippines 4024 Tel.: (049) 541-1470 (049) 541-3101 Fax: (049) 541-1180

Industries

Control Valve (CV) Troubleshooting / Refurbishing Bench Testing / Calibration of Positioners Training Program

Actuator Reassembly Actuator Reassembly

Step-by-step installation of each parts: Spring, Diaphragm, Shaft , etc. Upon reassembly, re-adjustment of bench range accordingly as stated on name plate. Checkup of valve actuator from air leakages applying maximum allowable pressure on the diaphragm
BRINGING QUALITY SERVICE FROM QUALITY-ORIENTED PEOPLE

OSA

OSA Industries Phils. Inc.

Unit 4-113 North Main Ave. cor. Commerce Rd Laguna Technopark Inc., Binan, Laguna Philippines 4024 Tel.: (049) 541-1470 (049) 541-3101 Fax: (049) 541-1180

Industries

Control Valve (CV) Troubleshooting / Refurbishing Bench Testing / Calibration of Positioners Training Program

Inspection of Actuator Inspection Assembly Assembly

Bench Range
3-15 psig 6-30 psig 7-15 psig 10-24 psig 10-30 psig

Allowable Pressure Spread (Psig)

3.0-4.5 6.0-8.0 6.0-8.0 8.5-11.5 8.5-11.5 13.0-16.0 26.5-31.5 13.5-16.5 22.0-27.0 26.5-31.5

BRINGING QUALITY SERVICE FROM QUALITY-ORIENTED PEOPLE

OSA

OSA Industries Phils. Inc.

Unit 4-113 North Main Ave. cor. Commerce Rd Laguna Technopark Inc., Binan, Laguna Philippines 4024 Tel.: (049) 541-1470 (049) 541-3101 Fax: (049) 541-1180

Industries

Control Valve (CV) Troubleshooting / Refurbishing Bench Testing / Calibration of Positioners Training Program

Proper mounting of actuator to the body with observance of as-found orientation. Travel length verification and correction as stated on the name plate or travel plate.

Completed Assembly of Control Completed Assembly of Control Valve Valve

BRINGING QUALITY SERVICE FROM QUALITY-ORIENTED PEOPLE

OSA

OSA Industries Phils. Inc.

Unit 4-113 North Main Ave. cor. Commerce Rd Laguna Technopark Inc., Binan, Laguna Philippines 4024 Tel.: (049) 541-1470 (049) 541-3101 Fax: (049) 541-1180

Industries

Control Valve (CV) Troubleshooting / Refurbishing Bench Testing / Calibration of Positioners Training Program

Seat leakage test according to ANSI B16.104/FCI 70.2 observing allowable leakage rate of a given CV. Hydrostatic shell test according to ANSI B16.34 or API 598 observing pressure rating and valve body material. Calibration of positioner according to normal operating conditions required by end user Control valve operation - Simulation

Testing and Testing and Calibration Calibration

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OSA

OSA Industries Phils. Inc.

Unit 4-113 North Main Ave. cor. Commerce Rd Laguna Technopark Inc., Binan, Laguna Philippines 4024 Tel.: (049) 541-1470 (049) 541-3101 Fax: (049) 541-1180

Industries

Control Valve (CV) Troubleshooting / Refurbishing Bench Testing / Calibration of Positioners Training Program

Bench Set and Testing Bench Set and Initial Actuator Spring Movement Final Actuator Spring Movement Travel Length Operation Leakage Test Procedure is witnessed by QA-QC Engineer Results are recorded on the Repair and Inspection Sheet

BRINGING QUALITY SERVICE FROM QUALITY-ORIENTED PEOPLE

OSA

OSA Industries Phils. Inc.

Unit 4-113 North Main Ave. cor. Commerce Rd Laguna Technopark Inc., Binan, Laguna Philippines 4024 Tel.: (049) 541-1470 (049) 541-3101 Fax: (049) 541-1180

Industries

Control Valve (CV) Troubleshooting / Refurbishing Bench Testing / Calibration of Positioners Training Program

Testing Of Control Valves According To The Following Testing Of Control Valves According To The Following Acceptance Criteria: Acceptance Criteria: ANSI B16.104 OR FCI 70.2 - For Seat Leakage Specifications ANSI B16.34 OR API 598 - For Hydrostatic Shell Testing

BRINGING QUALITY SERVICE FROM QUALITY-ORIENTED PEOPLE

OSA

OSA Industries Phils. Inc.

Unit 4-113 North Main Ave. cor. Commerce Rd Laguna Technopark Inc., Binan, Laguna Philippines 4024 Tel.: (049) 541-1470 (049) 541-3101 Fax: (049) 541-1180

Industries

Control Valve (CV) Troubleshooting / Refurbishing Bench Testing / Calibration of Positioners Training Program

(ANSI B16.104 OR FCI 70.2) SEAT LEAKAGE SPECIFICATIONS LEAKAGE CLASS MAXIMUM SEAT LEAKAGE
CLASS II CLASS III CLASS IV C LASS V C LASS VI

0.5% of rated valve capacity 0.5% of rated valve capacity 0.01% of rated valve capacity 5 x 10-4 per minute of water per inch of orifice diameter per PSI differential Leakage expressed in ml per minute versus port diameter for tight shut off (soft seat)
BRINGING QUALITY SERVICE FROM QUALITY-ORIENTED PEOPLE

OSA

OSA Industries Phils. Inc.

Unit 4-113 North Main Ave. cor. Commerce Rd Laguna Technopark Inc., Binan, Laguna Philippines 4024 Tel.: (049) 541-1470 (049) 541-3101 Fax: (049) 541-1180

Industries

Control Valve (CV) Troubleshooting / Refurbishing Bench Testing / Calibration of Positioners Training Program

Steel Valve Test Pressure (API 598)

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