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What are the shortcomings of conventional valve regulators?
Release time:
2026-04-07 15:22
Control valves serve as the final control element in a control system; any failure can directly compromise the safe operation of the unit and have a significant impact on the production process. The use of smart valve positioners can enhance the flow characteristics and performance of control valves, enable digital communication with DCS systems or fieldbus devices, strengthen the enterprise’s process control capabilities, and thereby ensure the safe and stable operation of the unit.
Shortcomings of Conventional Positioners
1) Conventional positioners generally operate on the principle of mechanical force balance, employing a nozzle–flapper mechanism with numerous moving parts. As a result, they are highly susceptible to disturbances such as temperature fluctuations and external vibrations, leading to poor environmental robustness. Moreover, the spring’s elastic coefficient can change under harsh operating conditions, introducing nonlinearity into the control valve and degrading control performance. External vibrations transmitted to the force-balance mechanism can cause component wear and drift in zero point and stroke, further compromising the positioner’s operational reliability.
2) Due to the inherent characteristics of the nozzle, the actuator consumes a significant amount of compressed air even in steady-state operation; consequently, when a large number of actuators are used, the overall energy consumption is substantial. Moreover, the nozzle itself is a potential failure source, as it can easily become clogged by dust or particulate contaminants, thereby preventing the positioner from functioning properly.
3) During routine manual adjustment of positioners, specialized equipment is required; it is impossible to do so without isolating the control loop. Moreover, adjustments to the zero point and stroke parameters mutually influence each other, necessitating repeated fine-tuning that is time-consuming and labor-intensive. When nonlinearity is severe, adjustment becomes even more challenging.
2020-01-19
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