FUNDAMENTALS OF CONTROL VALVES

CONTROL VALVE

A CONTROL VALVE IS A FINAL CONTROL ELEMENT AND A POWER OPERATED DEVICE WHICH MODIFIES THE FLOW RATE IN A PROCESS CONTROL SYSTEM.

ROLE OF A CONTROL VALVE

It is used for The correct distribution and control of Flowing fluid or gases Reduction of Pressure As a variable orifice As a throttling or modulating equipment

CONTROL VALVE PARTS

1. BODY 2. VALVE 3. ACTUATOR

BODY

The body is the pressure carrying part and it meets all their applicable pressure, temperature and corrosion requirements.

THE BODY PROVIDES THE PIPING CONNECTING ENDS FLUID FLOW PASSAGE WAY, AND SUPPORT THE SEATING SURFACE THE VALVE CLOSURE MEMBER

BODY- INTERNAL PARTS

GLAND PACKING

BODY FLANGE STEM WITH PLUG

INLET

OUTLET SEAT

TRIM

The trim of the valve consists of all the parts which will be wetted other than the body and the bonnet Trim is the heart of the valve with a primary function to proportion the valve orifice in such a manner that a prescribed relationship exists between flow capacity and valve plug lift The secondary function may be shut off tightly.

The trim includes Seat, Plug, Stem, Gland Follower, Gland Nut, Plug, Guide Bushings and Cage Stuffing box components considered as trim are the packing, follower, Spring, Lantern Ring, and Packing Retaining Ring. Secondary trim parts are stem to plug attachments , seat retaining ring, seat to body seals and spacers.

YOKE
.

A STRUCTURE BY WHICH THE DIAPHRAGM ASSEMBLY IS SUPPORTED RIGIDLY ON THE BONNET ASSEMBLY

YOKE
ACTUATOR BASE SPRING ADJUSTMENT SPRING BASE NUT STEM COUPLING POINTER TRAVEL SCALE BONNET BASE

ACTUATOR

ACTUATOR

UTILISES AIR PRESSURE / ELECTRIC POWER . HYDRAULIC PRESSURE TO ACT ON A DIAPHRAGM / PISTON AND DEVELOP A FORCE TO MOVE THE ACTUATOR STEM

ACTUTATOR CLASSIFICATION

PNUEMATICALLY OPERATED DIAPHARGM ACTUATOR PNUEMATICALLY OPERATED CYLINDER ACTUATOR MOTOR OPERATED PISTON ACTUATOR HYDRAULIC OPERATED PISTON ACTUATOR

ACTUATOR PARTS
VENT DIAPHRAGM DIAPHRAGM CASINGS ACTUATOR

PLATE
DIAPHRAGM INPUT SIGNAL

SPRING ACTUATOR STEM

SPRING SEAT YOKE STEM CONNECTOR INDICATOR GLAND STUDS SCALE SPRING ADJUSTER

LOCK NUT
BONET FLANGE

STUFFING BOX

GLOBE GLOBE GATE DIAPHRAGM PINCH OR CLAMP VALVE BALL ROTARY MOTION SEGMENTED BALL FULL BALL CYLIDRICAL PLUG TAPERED ECCENTRIC SPHERE

ANGLE
THREE-WAY

LINEAR MOTION

BUTTER FLY

Types of Vavles

Rotary Motion

Ball

Butterfly Linear Motion

Plug

Globe

Gate

Diaphragm

Pinch or Clamp

Globe

Angle

Three Way

IT IS MOSTLY COMMONLY USED ONE. IT IS A VALVE WITH A LINEAR CLOSURE MEMBER MOST COMMON TYPE CONTROL VALVE CLASSIFIED AS SINGLE SEATED AND DOUBLE SEATED SINGLE SEATED CONFORMS TIGHT SHUT OFF. DOUBLE SEATED VALVE IS HAVING HIGH RESISTANCE TO VIBRATION AND ABRASION.

IT HAVE THE ADVANTAGE OF EASY TRIM REMOVAL . IT IS TOP ENTRY VALVE WITH UNBALANCED, SINGLE-SEATED TRIM.

THE INNER VALVE PARTS CAN EASILY BE REMOVED AFTER REMOVING THE BONNET , BECAUSE ABSENCE OF INTERNAL THREADS.

ANGLE VALVES ARE SUITABLE FOR SLURRY FLUID ,

ADHESIVE FLUID AND HIGH VISCOSITY LIQUIDS.

SUITABLE FOR HIGH PRESSURE APPLICATION.

HAS STRONG RESISTANCE TO VIBRATION AND WEAR

IT IS SIMPLY DESIGN EXTENSION OF DOUBLE SEATED GLOBE VALVE.

DIVIDES FLOW IN TWO DIRECTIONS

CONVERGES TWO

STREAMS OF FLOW TO
ONE

APPLICABLE WHERE STRAIGHT THROUGH FLOW PATH , TIGHT SHUT OFF AND EASE OF OPERATION ARE REQUIRED.

MOST SUITABLE FOR HANDLING SLURRIES AS IT MINIMISES THE TENDENCY OF THE FLUIDS TO EITHER SETTLE OR STAIN .

SUITABLE FOR HIGH FLOW CAPACITY..

 IT OFFERS THE ADVANTAGES OF SIMPLICITY, LOW COST, LIGHT WEIGHT,AND SPACE SAVING.
IT CAN BE EASILY ADAPTED TO GIVE TIGHT SHUT-OFF . VALVE IS SUITABLE FOR LOW PRESSURE DROP

APPLICATIONS

ACTUATOR TORQUE REQUIRED IS LOWEST AS COMPARED TO OTHER VALVES . IT HAS MAXIMUM FLOW CAPACITY .

INSTALLATION AND HANDLING IS EASY .

The most common type of rotary valve used for control is the BUTTERFLY valve. The typical application range is in sizes from 2 through 36 or larger, for low or moderate pressures,or on unusual applications involving large flows at high static pressures ,but with limited pressure drop.

IT IS THE RELATION BETWEEN THE FLOW RATE THROUGH THE CONTROL VALVE AND PLUG TRAVEL , WHEN A CONSTANT PRESSURE DIFFERENTIAL IS MAINTAINED ACROSS THE VALVE
THIS IS ACHIEVED BY VARYING THE FLUID FLOW AREA WITH RESPECT TO THE SHAPE OF THE PLUG.

THE DESIGN OF A CONTROL VALVE TRIM IS BASED ON THE FLOW CHARACTERISTICS . DIFFERENT CHARACTERISTICS WHICH ARE COMMONLY SELECTED TWO TYPES 1. TWO POSITION (ON-OFF)CONTROL 2. THROTTLING CONTROL FLOW CHARACTERISTICS DECIDED BY SHAPE OF PLUG OR CAGE SLOTS.

THE PLUG IS THE MOVING COMPONENT OF THE VALVE WHICH THROTTLES FLOW BY POSITIONING ITSELF WITHIN THE SEAT ORFICE AND SHUTS OFF FLOW BY CONTACTING THE SEAT. THE PLUG IS MOVED AGAINST DYNAMIC FLUID FLOW

FORCES BY STEM FORCE TRANSMITTED FROM THE ACTUATOR. THE PLUGS (OR CAGE SLOTS) ARE SHAPED TO THROTTLE

FLOW WITH GIVEN CHARACTERSTICS SUCH AS

QUICK OPENING, LINEAR,

PARABOLIC OR EQUAL PERCENTAGE .

THREE TYPES OF VALVE CHARACTERESTICS ARE

QUICK OPENING :
This type of characteristics provides maximum change in flow rate at lower valve travels, as the plug bottom is flat with a fairly linear relationship , opening with a small signal will give the maximum flow rate Additional increase in valve travel gives sharply reduced changes in flow rate . The common application of the valve is ON -OFF

LINEAR CHARACTERSTICS: This type of valve provides change in flow rate which is linear with the valve lift. That is this proportional relationship produces a characteristics with constant slope so that with constant pressure drop , the valve gain is the same at all flow rates. Q = KX

EQUAL PERCENTAGE :( =% )

Equal increments of valve travel produce flow changes which are equal percentage of existing flow .
The change in flow rate is always proportional to the flow rate that exits just before the change in valve position is made . Q = Q0 emx Q0 = minimum controllable flow rate . m = ln R/T = constant for a particular valve R= rangeability , T= max. valve lift

Equal Percent = ( Present value - Previous

Q = Flow Rate

QO = Min Flow

QM = Max Flow

X = Valve Travel

m = ln R/T

mX

R/T

R=QM / QO

T=1

value) /
Previous value.
2.96 0.48 0.48 0.48 0.48 0.48 0.48 0.48 0.48 0.48 4.37 6.47 9.56 14.14 20.91 30.92 45.73 67.62 100.00 2 2 2 2 2 2 2 2 2 2 100 100 100 100 100 100 100 100 100 100 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 3.91 3.91 3.91 3.91 3.91 3.91 3.91 3.91 3.91 3.91 0.39 0.78 1.17 1.56 1.96 2.35 2.74 3.13 3.52 3.91 50 50 50 50 50 50 50 50 50 50 50 50 50 50 50 50 50 50 50 50 1 1 1 1 1 1 1 1 1 1

Linear Equal %

LIFT(%)
10 20 30 40 50 60 70 80 90 100

LINEAR
10 20 30 40 50 60 70 80 90 100

EQUAL %
2.96 4.37 6.47 9.56 14.14 20.91 30.92 45.73 67.62 100

Q.O
07 24 45 68 83 92 95 98 100 100

100 90 80

70

F L O W

60

50 40

30 20 10

10

30 20 % of valve opening

40

50

60

70

80

90

100

It is the number of US gallons per minute of water at 60 degree F that will pass through flow restriction at maximum opening maintaining a pressure drop of 1 psi.

BASIC FLOW RATE FORMULA FOR LIQUIDS IS: Q = K* A* SQRT {(P1-P2)/G} Q=Flow rate in gpm or Kg/hr p1=Upstream pressure in psig or Kg/cm2

p2=Downstream pressure in psig or Kg/cm2

G=Specific gravity at referred temperature K= DISCHARGE COEFFICIENT, A = AREA

IF G =1 AND P1-P2 = 1, THEN Q = K*A AS PER THE ABOVE DEFINITION, Cv = K*A

NOW Q = Cv * SQRT {(P1-P2)/G}

WHICH IS THE RELAVENT FORMULA OF FLOW

COEFFICIENT OF CONTROL VALVE IN CASE OF

LIQUIDS .
THE SAME PROCEDURE WILL BE ADOPTED IN CASE OF GAS FLOW , STEAM FLOW ETC. WITH SUITABLE MODIFICATION OF WORKING FORMULA.

It is effectively an index of pressure recovery in a control valve. i.e. High Cf values indicate low pressure recovery where a low Cf value indication of high pressure recovery . when fluid flows through the valve orifice , there is a marked increase in velocity . This velocity increase is accompanied by proportional decrease in pressure . Velocity reaches maximum and pressure a minimum at the smallest cross sectional flow area downstream of the orifice and that particular point is called vena contracta.

ORIFICEPLATE

--------------------------------------------------------------------------------------------------

VENA CONTRACTA

P2

PRESSURE

P1

PV

VENACONTRACTA VELOCITY

Control valves give problems mainly in three areas

1. Cavitation with associate noise and vibration 2. Flashing 3. Leakage of fluid around valve stem

Control valve selection is in step wise step 1 : calculate CV 1.select valve type step 2 : select valve size , trim size and characteristics.

Step 3 : select end connections

1. End connection type 2. End connection rating

Step 4 : select seat leakage that is class1/2/3/4/5.

Step5: select actuator type and size

step 6: select valve materials 1. Valve body material 2.trim material 3 seat construction as dictated by seat leakage 4. Guided bushing 5.soft seat materials for class vi leakage

Step 7 : select packing material and bonnet type

1.packing material a)standard Teflon asbestos

b)Teflon v- ring c)Grafoil 2. bonnet type

standard / extended / bellows seal extension

step8: select valve accessories

1.positioner
2.sov / volume booster / air set / lock up valve / volume tank / limit switch / travel stop ..etc

IN GENERAL, ALL MANUFACTURERS HAVE THEIR

OWN DESIGN DATA SHEETS, CONSIDERING THE CRITICAL FLOW , CAVITATION , FLASHING AND

VALVE NOISE OF THE GIVEN PROCESS CONDITION

WHEN THE CALCULATED Cv VALUE IS KNOWN, SELECTION AND SIZING OF CONTROL VALVE IS EASY.

AIR FILTER REGULATOR VALVE POSITIONER VOLUME BOOSTER QUICK EXHAUST AIR LOCK RELAY

LIMIT SWITCHES
SOLENOID VALVE POSITION TRANSMITTERS

POSITIONER :
The main function of positioner is to ensure that the control valve position is always proportional to the value of controller output signal regardless of packing box friction,actuator hysteresis the unbalanced forces of the plug.

USAGE OF VALVE POSITIONER: SMOOTH CONTROL CHANGING OF OPERATION MODE ACHIEVING SPLIT RANGE REDUCING TIME LAG

CHANGING VALVE CHARACTERSTICS

ACTION CAN BE REVERSED BY CHANGING THE PILOT.

SPRING BELLOWS DEFLECTION VALVE

NOZZLE
EXHAUST RELAY VALVE

STROKE

RESTRICTION I/P SIGNAL

C.V.STEM

FROM NOZZLE

TO BELLOWS

CLASS I CLASS II

NOT SPECIFIED 0.5% RATED VALVE CAPACITY 0.1 % RATED VALVE CAPACITY 0.01% RATED VALVE CAPACITY

CLASS III
CLASS IV CLASS V

5*10-4ml per min. OF WATER PER

INCH OF ORIFICE DIAMETER PER PSI DIFFERENTIAL LEAKAGE EXCPRESSED IN ML PER MINUTE VERSUS PORT DIAMETER

CLASS VI

1 2 2

AVOID

AVOID