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Fisher Controls International LLC

Fisher Controls 2005

General Specification
FGS 4L11
Revision B

Factory Performance Testing of Compressor


Antisurge Valves

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USE OF THIS DOCUMENT


The master copy of this document resides in electronic format. Printed
copies of this document are for convenience only. Verify that the revision
of this printed document matches the current revision of the electronic
master before use.
CONFIDENTIAL. This document, including the content, is the property of Fisher Controls and must be held in
strict confidence and properly safeguarded by the recipient at all times. It may not be copied or reproduced, or
provided or revealed to any other party, except with the prior written authorization of an appropriate officer of
Fisher Controls, and any authorized copy or reproduction must include this legend. The recipient may use the
same only for the purpose for which Fisher Controls has provided it to the recipient, and it must be returned to
Fisher Controls, along with all copies and reproductions, upon request or upon termination of use. By
accepting this document, the recipient agrees to the forgoing.

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Page 1 of 20

General Specification

FGS 4L11
Revision B

TABLE OF CONTENTS
1.

SCOPE ........................................................................................................................................... 4

2.

REFERENCES .............................................................................................................................. 4

3.

PURPOSE...................................................................................................................................... 4

4.

PERFORMANCE SPECIFICATION ....................................................................................... 4

5.

VALVE ASSEMBLY CLASS DEFINITIONS ........................................................................ 6


5.1 Class A ...................................................................................................................................... 6
5.2 Class B....................................................................................................................................... 6
5.3 Class C ...................................................................................................................................... 6

6.

FACTORY ACCEPTANCE TEST SERIES DEFINITIONS................................................. 6


6.1 Advanced FAT......................................................................................................................... 6
6.2 Basic FAT.................................................................................................................................. 6

7.

TEST SETUP PROCEDURES ................................................................................................... 7


7.1 Valve Assembly ...................................................................................................................... 7
7.2 Actuator Assembly ................................................................................................................. 7
7.3 Positioner / Trip System ........................................................................................................ 8
7.4 Data Acquisition System....................................................................................................... 8
7.5 Static Calibration .................................................................................................................... 8
7.6 Valve Friction .......................................................................................................................... 8

8.

TEST PROCEDURES AND ACCEPTANCE CRITERIA .................................................... 8


8.1 Terminal Based Linearity...................................................................................................... 9
8.2 Stroking Time Under Positioner Control ........................................................................ 10
8.3 Stroking Time Under SOV Trip ........................................................................................ 12
8.4 Large Amplitude Step Response ....................................................................................... 13
8.5 Response to a 5 Minute Ramp............................................................................................ 14
8.6 Small Amplitude Step Response....................................................................................... 16
8.7 Maximum Control Signal Change to Initiate Movement off the Seat....................... 17
8.8 Supply Pressure Droop ....................................................................................................... 18
8.9 Frequency response.............................................................................................................. 19

9.

RELEASE/REVISION RECORD ............................................................................................ 20

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General Specification

FGS 4L11
Revision B

TABLE OF FIGURES
Figure 1: Typical stroking time measurement when an upper air cushion is present. ............ 11
Figure 2: Test signal to evaluate large amplitude response.......................................................... 13
Figure 3: Characterization of stick-slip motion. ............................................................................. 15
Figure 4: Blocked sinusoid test signal .............................................................................................. 16

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General Specification

FGS 4L11
Revision B

1. SCOPE
This specification details factory acceptance test procedures and acceptance criteria for
evaluating and documenting static performance, dynamic performance, and servo
robustness. Test procedures and acceptance criteria defined in this document are designed to
quantify performance of fully assembled valves and actuators in their as shipped
conditions.
These specifications do not supersede customer requirements but are to be used in
conjunction with customer requirements.
2. REFERENCES
(a)

FGS 4L8, Valve Signature Performance Standards.

(b)

ISA-26-1968, Dynamic Response Testing of Process Control Instrumentation.

(c)

ISA-75.13-1996, Method of Evaluating the Performance of Positioners with Analog


Input Signals and Pneumatic Output.

(d)

ANSI / ISA TR75.25.02-2000, Control Valve Response Measurement from Step


Inputs.

(e)

ANSI / ISA 75.25.01-2000, Test Procedure for Control Valve Response


Measurement from Step Inputs.

(f)

ANSI / ISA -51.1-1979 (R1993), Process Instrumentation Terminology.

(g)

Antisurge System Dynamic Characteristics, Nuovo Pignone performance


specification, Item N. SOK6747403/4, Rev. 0, issued 16/12/03.

3. PURPOSE
Antisurge valve performance has traditionally been defined by stroking time in the opening
direction. However, antisurge controller technology has advanced rapidly and increasingly
sophisticated control algorithms now allow compressors to operate closer to surge limits
without increasing the risk of initiating a surge event. As antisurge controllers and control
objectives have advanced, new demands have been placed on antisurge valves. This
document provides guidelines and test procedures to ensure that antisurge valves meet static
performance, dynamic performance, and servo robustness requirements necessary for
smooth startup and reliable operation.
4. PERFORMANCE SPECIFICATION
A summary of the antisurge valve performance specifications is presented in Table 1.
Engineering contractors, end users, or compressor manufacturers may have additional
requirements or requirements that supersede those listed in this table. Variations from the
requirements listed in Table 1 should be documented and agreed to by Fisher Engineering.
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Fisher Controls International LLC

Fisher Controls 2005

Table 1: Antisurge valve performance specification


Req.
No.

Description

Specification

Notes

Stroking time in the opening direction by positioner control in


response to a step change from 20 mA to 4 mA.

2 sec

Inclusive of dead time.

Stroking time in the closing direction by positioner control in


response to a step change from 4 mA to 20 mA.

3 sec

Inclusive of dead time.

Stroking time in the opening direction in response to a solenoid


trip.

1 sec. preferred
1.5 sec max
0.4 sec

Opening dead time.

Large amplitude response to 10%, 20%, 30%, , 80% step changes


from a baseline of 10%.

Valve response to a 20 % / min. ramp signal from 20 mA to 4 mA


and from 4 mA to 20 mA.

Valve movement in response to a 1% blocked sinusoid from a


baseline of 5% and a baseline of 50%.

Terminal based linearity.

1%

Maximum control signal change to initiate movement off the seat.

2%

10

Maximum allowable supply pressure droop during a full stroke


test from 20 mA to 4 mA and during a full stroke test from 4 mA
to 20 mA.

5 psig above trip point

11

Frequency response test with a swept sinusoid command signal


centered at 50% with a 10% amplitude.

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Max. 1 overshoot per step 3% of calibrated


span. Minimal overshoot in the closing
direction.
No stick-slip motion.
Valve shall respond bidirectionally.
Measured with an independent
travel sensor.

Magnitude and phase plots to be continuous


with no resonant peaks or dropouts.
Magnitude to be 0 dB at 180 phase shift.

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Based on minimum design


supply pressure.

Fisher Controls International LLC

Fisher Controls 2005

5. VALVE ASSEMBLY CLASS DEFINITIONS


This section defines three valve assembly classes for testing.
5.1 Class A
Class A assemblies will meet all static performance, dynamic performance, and servo
robustness criteria listed in Table 1. Only valve assemblies approved by Fisher Engineering
are eligible to be tested to Class A. Deviations from acceptance criteria must be approved by
the customer.
5.2 Class B
Class B assemblies are those that fall outside of Class A guidelines but are designed to meet
the requirements listed in Table 1 as closely as possible. Only valves assemblies approved by
Fisher Engineering are eligible to be tested to Class B. Class B assemblies will meet stroking
time requirements 1, 2, and 3 listed in Table 1. Requirements 4 11 will be tested but minor
variations from the specifications will be allowed and will not require customer approval.
5.3 Class C
Class C assemblies are those where the performance specifications in Table 1 are not
applicable. Stroking time requirements will be specified by the customer and the valve will
be tested to ensure that it complies. Customers can define additional criteria as listed in
Table 1 to be tested, but results will be used for reference only.
6. FACTORY ACCEPTANCE TEST SERIES DEFINITIONS
This section defines two factory acceptance test (FAT) series for quantifying static
performance, dynamic performance, and servo robustness. Tests to be performed for each
assembly class are summarized in Table 2.
6.1 Advanced FAT
This test series fully evaluates and documents compliance relative to all performance
specifications defined in Table 2. The advanced test series is appropriate for critical, difficult,
or unique applications. Examples include long-stroke actuators and actuators with a large
number of accessories. Test Summary Form is in eDocs; FORM_FGS4L11a
6.2 Basic FAT
This is an abbreviated test series that provides a more economical way of validating
compliance with the performance specifications defined in Table 2. This test series is
appropriate for most antisurge control valves. Test Summary Form is in eDocs;
FORM_FGS4L11b

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FGS 4L11

General Specification

Revision B
Table 2: Basic and Advanced FAT test schedule
Req.
Short Description
1
Stroking time open

Class A
Adv Basic
9
9

2
3
4
5
6

Stroking time closed


SOV stroking time
Opening dead time
Large amplitude response
5 min. ramp

9
9
9
9
9

9
9

Small amplitude response

8
9
10
11

Linearity
Max. ctrl. signal off seat
Supply droop
Frequency response

9
9
9
9

Class B
Adv Basic
9
9

Class C
Adv
Basic
9
9

9
9
9
9
9

9
9

9
9
9
9

9
9
9
9

9
9
9
9
9

9
9

7. TEST SETUP PROCEDURES


Antisurge valves are to be tested on a complete valve and actuator assembly in its as
shipped condition.
7.1 Valve Assembly
(a)

Performance tests are to be run on a fully assembled valve.

(b)

Valve is to include a complete set of trim, including the valve plug, cage, piston
rings, seat ring, and plug seal.

(c)

Valve packing is to be tightened in accordance with Fishers documented practices.

7.2 Actuator Assembly


(a)

Actuator is to be configured with the manufacturers recommended accessories.


Hard piping is not required.

(b)

Volume tanks and other external pieces of equipment may be hooked up using
temporary hoses.

(c)

Supply pressure is to be set according to the manufacturers recommendations.

(d)

Total stem travel shall be set to the specified design value -0", +1/32.

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General Specification

FGS 4L11
Revision B

7.3 Positioner / Trip System


(a)

Command signal and power to the positioner are to be independent of the power to
the trip system.

(b)

Unless otherwise specified, positioner is to be configured so the valve opens on loss


of power or loss of air supply to the positioner.

(c)

Unless otherwise specified, trip system is to be configured for fail open action on
loss of supply pressure or on loss of power.

7.4 Data Acquisition System


(a)

Stem position is to be measured with an external position transducer that is


independent of the positioner servo control loop.

(b)

Analog command signals are to be used for testing. Digital set point changes are
not acceptable.

(c)

For accuracy, laboratory-grade instrumentation shall be used to measure stem


travel. An external position transducer, such as a Celesco PT8600 series encoder or
equivalent should be used. Resolution is to be 0.0001-in. or better.

(d)

Command signal to the positioner and stem travel are to be recorded at a minimum
sample frequency of 100 Hz.

7.5 Static Calibration


(a)

Positioner is to be calibrated in accordance with recommended practices document


in the manufacturer's instruction manual.

(b)

Unless otherwise specified, full seat load must be obtained at 20.00 mA, full
actuator load must be obtained at 4.00 mA.

7.6 Valve Friction


Friction of the fully assembled control valve is to be estimated using the latest
available version of ValveLink. If an actuator assembly is equipped with volume
boosters, friction should be estimated with the bypass screws on the boosters opened
up completely and the dynamic scan time set to 400 sec. This will minimize biases in
pressure measurements due to pressure drops across the booster bypasses.
8. TEST PROCEDURES AND ACCEPTANCE CRITERIA
Test procedures and acceptance criteria to assess compliance are detailed in this section. In
the following text, 0% travel refers to the fully closed valve position and 100% refers to the
fully open valve position. Test procedures have been put in an order that will minimize test
time.

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FGS 4L11

General Specification

Revision B
8.1 Terminal Based Linearity
8.1.1 Requirement No.
8
8.1.2 Test Schedule
Assembly Class
Test Series
Test Required

Adv

Basic

Adv

Basic

Adv

Basic

8.1.3 Test Procedure


(a)

Move the valve to 0% and zero the external position transducer.

(b)

Move the valve to 100% and record travel.

(c)

Move the set point to 10% and wait for steady-state conditions.

(d)

Adjust the set point to the positioner from 10% to 90% in increments of 10%. Set
point changes must be applied so that neither set point nor travel overshoot their
intended target.

(e)

At each steady-state position, record actual stem travel from the external sensor.

(f)

Repeat in the reverse direction for set points ranging from 90% to 10% in
decrements of 10%.

(g)

Linearity results are to be plotted on a deviation plot with command signal in


percent of span on the abscissa and difference between measured travel and ideal
travel expressed as a percent of span plotted on the ordinate.

8.1.4 Acceptance Criteria


(a)

Calibrated travel span should be equal to design -0 in, +1/32 in.

(b)

Terminal based linearity is to be +/-1% of calibrated span.

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FGS 4L11

General Specification

Revision B

8.2 Stroking Time Under Positioner Control


8.2.1 Requirement Nos.
1, 2, and 4. Requirement 4 is for advanced FAT only.
8.2.2 Test Schedule
Assembly Class

Test Series

Adv

Basic

Adv

Basic

Adv

Test Required

Basic
9

8.2.3 Test Procedure


(a)

Set the command signal 20 mA and wait for the actuator pressures to reach full seat
load.

(b)

Apply a step change from 20 mA to 4 mA and record the response for 30 seconds.

(c)

Apply a step change from 4 mA to 20 mA and record the response for 30 seconds.

8.2.4 Acceptance Criteria


(a)

Stroking time in the opening direction is measured from the time the command
signal changes to the time the upper travel stop is first engagedor, if an upper air
cushion is present, to the time when the air cushion is first engaged. Stroking time
in the opening direction under positioner control is to be 2 sec.

(b)

Stroking time in the closing direction is measured from the time the command
signal changes to the time the plug first engages valve seat or, if a lower air
cushions is present, to the time when the lower air cushion is first engaged.
Stroking time is to be 3 sec.

(c)

For the Advanced FAT only, dead time off the seat -- measured from the time the
command signal changes to the time of the first observable response in travel -must be 0.40 sec.

Note: Figure 1 illustrates a typical response trace from an actuator equipped with an upper air
cushion. Stroking time is measured from the time the command signal changes to the time the air
cushion is first engaged.

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FGS 4L11

General Specification

Revision B

110
100
90

Top Air Cushion


Engaged

80
70

Input
Travel
(%)

102
100
98
Input 96
Travel 94
(%)
92
90
88
86

60
50
40
30

6.4

20

6.5

6.6

6.7

6.8

6.9

7.0

Time (sec)

10
Stroking Tiime = 1.66 s

0
-10
4.5

5.0

5.5

6.0

6.5

7.0

7.5

8.0

Time (sec)

Figure 1: Typical stroking time measurement when an upper air cushion is present.

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FGS 4L11

General Specification

Revision B

8.3 Stroking Time Under SOV Trip


8.3.1 Requirement No.
3
8.3.2 Test Schedule
This test is only to be run on those assemblies equipped with solenoid operated valves. For
those assemblies without solenoids, this test may be skipped.

Assembly Class

Test Series

Adv

Basic

Adv

Basic

Adv

Basic

Test Required

8.3.3 Test Procedure


(a)

Set the command current to the positioner to 20 mA and wait until full actuator seat
load has been obtained.

(b)

With the command current at 20 mA, remove power from the SOV and record the
response for 30 seconds.

(c)

Restore power to the SOV and record the response for 30 seconds.

8.3.4 Acceptance Criterion


Stroking time in the opening direction is measured from the time the SOV was deenergized to the time the valve stem reaches 98% of calibrated travel span command
or, if an upper air cushion is present, to the time when the air cushion is first engaged.
Stroking time in the opening direction under SOV trip is to be 1.5 sec.

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FGS 4L11

General Specification

Revision B
8.4 Large Amplitude Step Response
8.4.1 Requirement No.
5
8.4.2 Test Schedule
Assembly Class
Test Series
Test Required

Adv

Basic

Adv

Basic

Adv

Basic

8.4.3 Test Procedure


(a)

Move the valve to 10% set point and wait for steady-state conditions

(b)

Figure 2 illustrates the test signal for evaluating large amplitude response.
Bidirectional steps are initiated from a baseline of 10%. Step sizes range from 10%
to 80% in increments of 10%. Hold time for each step is to be 15 sec.

Figure 2: Test signal to evaluate large amplitude response.


8.4.4 Acceptance Criteria
(a)

Overshoot, which is defined as the maximum travel excursion beyond the final,
steady-state value is to be less than 3.0% of calibrated travel span.

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FGS 4L11

General Specification

Revision B
8.5 Response to a 5 Minute Ramp
8.5.1 Requirement No.
6
8.5.2 Test Schedule
Assembly Class

Test Series

Adv
9

Test Required

B
Basic

Adv
9

C
Basic

Adv

Basic

8.5.3 Test Procedure


(a)

Move the valve to its full closed position and wait for the actuator pressure to reach
steady-state conditions.

(b)

Ramp the command signal from 20 mA to 4 mA over 5 minutes.

(c)

At the top of the stroke, wait for the actuator pressure to reach steady-state
conditions.

(d)

Ramp the command signal from 4 mA to 20 mA over 5 minutes.

(e)

Plot travel against velocity with travel in percent of calibrated span on the abscissa
and velocity and command ramp rate in percent of calibrated span per second on
the ordinate.

8.5.4 Acceptance Criterion


(a)

Note:

No stick-slip motion. The largest change in travel between two successive,


continuous periods at zero velocity -- excluding travel stops -- is the maximum
stick-slip motion in percent of calibrated travel span.
Stick-slip motion occurs when static friction exceeds dynamic friction. Figure 3 illustrates
typical stick-slip motion for a ramp signal. The acceptance criterion is defined by the
maximum change in travel between successive, extended zero velocity regions, excluding
travel stops.

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General Specification

FGS 4L11
Revision B

Figure 3: Characterization of stick-slip motion.

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FGS 4L11

General Specification

Revision B

8.6 Small Amplitude Step Response


8.6.1 Requirement No.
7
8.6.2 Test Schedule
Assembly Class
Test Series
Test Required

Adv

Basic

Adv

Basic

Adv

Basic

8.6.3 Test Procedure


(a)

This test will be performed at nominal set points of 5% and 50%.

(b)

Starting from a set point lower than nominal, slowly move the set point to the
nominal set point and wait for valve to reach steady-state conditions. During
initialization, neither the command signal nor stem travel should reverse directions.

(c)

Apply a 1% blocked sinusoid test signal (Figure 4) with individual step hold times
of 45 seconds and record the response.

Figure 4: Blocked sinusoid test signal

8.6.4 Acceptance Criteria


(a)

Valve shall respond to step changes in both the opening and closing directions.

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FGS 4L11

General Specification

Revision B
8.7 Maximum Control Signal Change to Initiate Movement off the Seat
8.7.1

Requirement No.
9

8.7.2 Test Schedule


Assembly Class

Test Series

Adv
9

Test Required

B
Basic

Adv
9

C
Basic

Adv

Basic

8.7.3 Test Procedure


(a)

Move the valve to its fully closed position at 20 mA and wait for the actuator
pressure to reach its full seat load.

(b)

Apply a step change to the set point from 20 mA to 19.68 mA (2% change). Record
valve response for 60 seconds.

8.7.4 Acceptance Criterion


(a)

The valve shall respond to the 2% set point change.

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FGS 4L11

General Specification

Revision B

8.8 Supply Pressure Droop


8.8.1 Requirement No.
10
8.8.2 Test Schedule
This test is only to be run on those assemblies equipped with pneumatic trips, such as
a Fisher Type 377. For those assemblies without pneumatic trips, this test may be
skipped.

Assembly Class

Test Series

Adv
9

Test Required

B
Basic

Adv

C
Basic

Adv

Basic

8.8.3 Test Procedure


(a)

Install an independent pressure sensor on an air supply line downstream of the


pressure regulator and as close to the SOV trip as practical. Temporary hosing from
the SOV inlet to the supply connection may be used.

(b)

Set the regulator to minimum design supply pressure.

(c)

Move the valve to its full closed position at 20 mA and wait for the actuator
pressure to reach its full seat load.

(d)

Apply a step change from 20 mA to 4 mA and record data for 30 seconds.

(e)

Apply a step change from 4 mA to 20 mA and record data for 30 seconds.

(f)

Restore regulator to nominal supply pressure set.

8.8.4 Acceptance Criterion


(a)

Supply pressure shall not fall below trip point setting plus 5 psig.

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FGS 4L11

General Specification

Revision B

8.9 Frequency response


8.9.1 Requirement No.
11
8.9.2 Test Schedule
Assembly Class
Test Series
Test Required

A
Adv
9

B
Basic

Adv

C
Basic

Adv

Basic

8.9.3 Test Procedure


(a)

Move the set point to 50% (12 mA) and wait for steady-state conditions.

(b)

Apply a sinusoidal test signal with a 10% (20% peak-to-peak) amplitude.

(c)

Record at least two cycles at 0.01 Hz, 0.02 Hz, 0.03 Hz, and four cycles from 0.12 Hz
in increments of 0.08 Hz. until -180 deg. phase shift is observed.

(d)

Generate a Bode magnitude plot with the ratio of travel (%) and input (%) scaled to
dB on the ordinate and frequency on the abscissa. Frequency should be plotted on
a common log scale.

(e)

Generate a Bode phase angle plot with phase angle (deg.) on the ordinate and
frequency on the abscissa. Frequency should be plotted on a common log scale.
Acceptance Criteria

8.9.4 Acceptance Criteria


(a)

Gain dropout versus frequency shall be continuous with no resonant peaks.

(b)

Magnitude at -180 deg. phase shift shall be 0 dB or less.

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General Specification

FGS 4L11
Revision B

9. RELEASE/REVISION RECORD
Release/Revision: A
Date:
12 July 2005
Written by:
Ken Junk
Approved:
Mike Lovell
Date Approved:
12 July 2005
Department:
Advanced Technology
Revision:
Date Revised:
Revised by:
Checked by:
Date Checked:
ECRN:
Reason:

Printed: 6-Sep-05

24 August 2005
Ken Junk
Chris Metschke
31 August 2005
051212
Corrected various formatting errors. Sections 7.2(d) and 8.1.4(a) were
updated to be consistent with current Fisher manufacturing practices.
Section 8.1.3(c) was added for clarification. Definition of stroking time in
Sections 8.2.4(a) and 8.2.4(b) were updated and made more rigorous.

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