Employed in a wide range of industrial applications,
limit switches are known for ease of installation,
simple design, ruggedness, and reliability.
Courtesy Flowserve Automax
Valves, devices used for controlling flow, are motion based. The movable portions of valve trim create some degree of obstruction to media flow, providing regulation of the passage of the media through the valve. It is the movement of critical valve trim elements that limit switches are used to indicate or control. The movable valve trim elements commonly connect to a shaft or other linkage extending to the exterior of the valve body. Mounting electric, hydraulic, or pneumatic actuators to the shaft or linkage provides the operator a means to drive the mechanical connection, changing the orientation or position of the valve trim and regulating the media flow. Because of its positive connection to the valve trim, the position of the shaft or linkage is analogous to the trim position and can be used to indicate what is commonly referred to as “valve position”. Limit switches are easily applied to the valve shaft or linkage in a manner that can provide information or direct functional response to certain changes in valve position.
In industrial valve terms, a limit switch is a device containing one or more magnetic or electrical switches, operated by the rotational or linear movement of the valve.
What are basic informational elements that can be relayed to the control system by limit switches? Operators of an industrial process, for reasons of efficiency, safety, or coordination with other process steps, may need answers to the following basic questions about a process control valve:
- Is the valve open?
- Is the valve closed?
- Is the valve opening position greater than “X”?
- Has the valve actuator properly positioned the valve at or beyond a certain position?
- Has the valve actuator driven the valve mechanism beyond its normal travel limits?
- Is the actuator functioning or failing?
Applying limit switches to industrial valve applications should include consideration of:
- Information Points – Determine what indications are necessary or useful for the effective control and monitoring of valve operation. What, as an actual or virtual operator, do you want to know about the real time operational status of a valve that is remotely located. Schedule the information points in operational terms, not electrical switch terms.
- Contacts – Plan and layout a schedule of logical switches that will provide the information the operator needs. You may not need a separate switch for each information point. In some cases, it may be possible to derive needed information by using logical combinations of switches utilized for other discrete functions.
- Environment – Accommodate the local conditions and hazards where the switch is installed with a properly rated enclosure.
- Signal – The switch rating for current and voltage must meet or exceed those of the signal being transmitted.
- Duty Cycle – The cycling frequency must be considered when specifying the type of switch employed. Every switch design has a limited cycle life. Make sure your selection matches the intended operating frequency for the process.
- Auxiliary Outputs – These are additional contact sets that share the actuation of the primary switch. They are used to transmit additional signals with specifications differing from the primary signal.
- Other Actuator Accessories – Limit switches are often integrated into an accessory unit with other actuator accessories, most of which are related to valve position. A visual local indication of valve position is a common example.
Employing a properly configured valve automation package, with limit switches delivering valve status or position information to your control system, can yield operational and safety benefits for the life of the unit. Good advice is to consult with a valve automation specialist for effective recommendations on configuring your valve automation accessories to maximize the level of information and control.