Control Valve Calibration Report (Positioner Stroke Check) Template
A stroke check record for control valves with positioners. Enter the measured travel at each signal; the sheet converts it to % open, calculates the position error and checks the tolerance.
Download
- How to Use sheet with steps
- Template sheet, blank and ready
- Example sheet, filled in
- 112 built in formulas
- A4 landscape print setup
- Works in Excel, Google Sheets and LibreOffice
Preview of the Filled Example
This is the Example sheet from the download, so you can see exactly how the completed control valve calibration report (positioner stroke check) looks.
Stroke check (direct acting: 4 mA closed, 20 mA open)
| Signal (%) | Signal (mA) | As found travel (mm) | As found position (%) | As found error (%) | As left travel (mm) | As left position (%) | As left error (%) | Result |
|---|---|---|---|---|---|---|---|---|
| 0 | 4.00 | 0.0 | 0.0 | 0.0 | 0.0 | 0.0 | 0.0 | PASS |
| 25 | 8.00 | 10.9 | 27.2 | 2.2 | 10.0 | 25.0 | 0.0 | PASS |
| 50 | 12.00 | 20.8 | 52.0 | 2.0 | 20.1 | 50.2 | 0.3 | PASS |
| 75 | 16.00 | 30.7 | 76.8 | 1.8 | 30.0 | 75.0 | 0.0 | PASS |
| 100 | 20.00 | 39.4 | 98.5 | −1.5 | 40.0 | 100.0 | 0.0 | PASS |
| 75 | 16.00 | 30.9 | 77.2 | 2.2 | 30.1 | 75.2 | 0.2 | PASS |
| 50 | 12.00 | 21.1 | 52.8 | 2.8 | 20.1 | 50.2 | 0.3 | PASS |
| 25 | 8.00 | 11.2 | 28.0 | 3.0 | 10.1 | 25.2 | 0.2 | PASS |
| 0 | 4.00 | 0.3 | 0.8 | 0.8 | 0.0 | 0.0 | 0.0 | PASS |
About the Control Valve Calibration Report (Positioner Stroke Check)
A control valve that does not go where the controller tells it to causes poor control, oscillation and energy loss. This report checks that the valve position follows the 4 to 20 mA signal across the full stroke, upscale and downscale, which also shows friction and dead band in the valve and actuator.
How to fill in this template
- Enter the rated travel from the valve nameplate and the allowed position tolerance.
- With the process isolated and the valve safe to stroke, inject each signal with a mA source or from the DCS.
- Measure the stem travel with a scale or dial gauge (or read the positioner travel) and type it in As found travel (mm).
- If errors exceed tolerance, run the positioner auto calibration or adjust zero and span, then record As left travel.
- Time a full open and close stroke and complete the functional checks before returning the valve to service.
What the formulas do
- Signal (mA) = 4 + 16 × signal % ÷ 100.
- Position (%) = measured travel ÷ rated travel × 100.
- Error (%) = position % − signal %. PASS when within tolerance (as left values used when present).
Related tools
Frequently Asked Questions
How often should control valves be stroke checked?
At every turnaround and after any positioner or actuator work, and more often for critical loops.
What tolerance is typical for a control valve stroke check?
± 1 % of travel is common with modern digital positioners; ± 2 % for older pneumatic positioners.
What causes a difference between upscale and downscale positions?
Packing friction and dead band. A large difference points to tight packing, a sticking stem or positioner problems.
Learn more on the blog
Positioner calibration: 8 proven steps for reliable valves
A practical guide on instrumentationblog.in that explains the procedure behind this template and how engineers apply it on real plants.
Read Full Article