T227/U03/ PPP 3

Correcting Units

Prof. S.J.Gambhire, MANET, Pune 1

 Types of Control Valve
1. On the basis of body construction:
a) Globe Valve
-single seated
-double seated
-cage type
Single seated Valves are suitable for low pressure applications.
Double seated for High Pressure drop applications.
• only one plug is present in the control valve, so it is single seated valve.
• The advantage of this type of valve is that, it can be fully closed and flow
variation from 0 to 100% can be achieved.
• But looking at its construction, due to the pressure drop across the orifice
a large upward force is present in the orifice area, and as a result, the
force required to move the valve against this upward thrust is also large.
• Thus this type of valves is more suitable for small flow rates.

Prof. S.J.Gambhire, MANET, Pune 2

Prof. S.J.Gambhire, MANET, Pune 3
Prof. S.J.Gambhire, MANET, Pune 4
• On the other hand, there are two plugs in a double-seated valve;
flow moves upward in one orifice area, and downward in the
other orifice.
• The resultant upward or downward thrust is almost zero.
• As a result, the force required to move a double-seated valve is
comparatively much less.
• But the double-seated valve suffers from one disadvantage.
• The flow cannot be shut off completely, because of the
differential temperature expansion of the stem and the valve
seat.
• If one plug is tightly closed, there is usually a small gap between
the other plug and its seat.
• Thus, single-seated valves are recommended for when the
valves are required to be shut off completely.
• But there are many processes, where the valve used is not
expected to operate near shut off position.
• For this condition, double-seated valves are recommended.

Prof. S.J.Gambhire, MANET, Pune 5

 b) Angle Valve
- Single seated
-Cage type :- These valves are good for high pressure drop
applications . These valves can be used at the bends eliminating the use of an
Elbow.
c) Three way Valve
-Mixing Service
-Diverting service
d) Butterfly Valve
-Wafer type
-Flange type :- These valves are used where flow is large and
pressure drop across valve is very low.
Some other types include:
• Saunders type - For Corrosive service
• Ball type - For Pulp
• Complex type - Combination of Globe and Butterfly valve
Prof. S.J.Gambhire, MANET, Pune 6
• Control Valve

Prof. S.J.Gambhire, MANET, Pune 7

• Valve A are air to close type, indicating, if the air fails, the valve will be
fully open.
• Opposite is the case for valve B.

Prof. S.J.Gambhire, MANET, Pune 8

 Flow Characteristics of Control Valve

• It describes how the flow rate changes with the movement or lift of the
stem.
• The shape of the plug primarily decides the flow characteristics.
• However, the design of the shape of a control valve and its shape requires
further discussions.
• The flow characteristic of a valve is normally defined in terms of
• (a) inherent characteristics and
• (b) effective characteristics.
• An inherent characteristic is the ideal flow characteristics of a control
valve and is decided by the shape and size of the plug.
• On the other hand, when the valve is connected to a pipeline, its overall
performance is decided by its effective characteristic.

Prof. S.J.Gambhire, MANET, Pune 9

 Depending upon the Inherent flow characteristics , the control valve may
be categorized as:
I. Quick Opening valve
II. Linear Valve
III. Equal Percentage Valve
Quick opening characteristics :
A control valve having these characteristics is primarily used for Full On and
Off control applications. In such a valve, relatively small motion of the valve
stem give maximum possible flow rate through the valve.
Linear Characteristics :
In the valves of linear characteristics, the flow is directly proportional to the
valve travel.
Equal Percentage Characteristics:
In the valves of equal percentage characteristics, the flow change to the lift is
small when the valve travel is small. As the valve travel becomes larger, the
flow change corresponding to the same lift tends to become greater.
Prof. S.J.Gambhire, MANET, Pune 10
Fig.: Inherent flow characteristics

Prof. S.J.Gambhire, MANET, Pune 11

• Rangeability :
It is defined as the ratio of Maximum controllable flow to the Minimum
controllable flow.
• Turndown:
It is ratio of the Normal maximum flow to the Minimum controllable flow.
Turndown = 0.7 x Rangeability
• Actuators
• An actuator is defined to be that portion of a valve which respond to
applied signal and causes the motion resulting in modification of fluid
flow. Thus an actuator is any device which causes the valve stem to
move.
• It can be operated in following ways:
Manually
Pneumatically
Hydraulically
Electrically
Hybrid operated Prof. S.J.Gambhire, MANET, Pune 12
• Function of a Actuator : In a valve assembly, an actuator serves a dual
function
1. It responds to an external signal directed to it. This then causes the
desired movement of the inner valve.
2. The actuator provides a convenient support for certain valve accessory
item, such as positioners, limit switches, solenoid valves and local
controllers.
• Electrical Actuators : Important Electrical Actuators are as Follows:
1. Solenoid – It is a device used for conversion of electrical signal into
mechanical motion .
2. Electrical Motors – The motor accepts electrical inputs and gives
continuous rotation as the output.
3.Stepper Motor – It is a rotating machine that completes a full rotation by
sequencing through a series of discrete rotational steps. Each step position
is an equilibrium position. This is due to the fact that the rotor position will
stay at the latest position without further excitation.
They are widely used due to their ease of interfacing with digital circuits.
Prof. S.J.Gambhire, MANET, Pune 13
Diaphragm type Pneumatic Actuator

Prof. S.J.Gambhire, MANET, Pune 14

• This actuator is a completely separable device independent of the valve
body.
• When the air is applied to the top of the diaphragm through the
amplifying pilot, the actuator stem is pushed down. This motion is
opposed by compression spring.
• Let the input pressure increase, this moves the input bellow to the right,
so that the flapper covers the nozzle. Hence the back pressure of the
nozzle changes. This change is transmitted to the diaphragm. Thus the
diaphragm moves down.
• The feedback lever attached to the actuator stem compresses the spring
and makes the flapper to return to a equilibrium position.
• Thus the actuator stem assumes a position dictated by input air pressure.

Prof. S.J.Gambhire, MANET, Pune 15

Piston Cylinder type Actuator

Prof. S.J.Gambhire, MANET, Pune 16

• This actuator uses a piston within the cylinder. Fixed and variable air
pressure acts on the cylinder to balance the fluid force on the valve.
• They are of two types:
1. Cushion Loaded Piston Actuator – In this, a fixed air pressure known as
cushion pressure is opposed by variable air pressure. This results in
balancing of fluid forces on the valve.
2. Double Acting Piston Actuator – In this two opposing variable air
pressure are used to balance the liquid forces on the valve.
• In this case, the pilot is a spool valve requiring an air supply of 30 to 100
psig.
• When the input pressure increases, the bellow moves to the right and
pushes the pilot upwards.
• Hence the upper side of the cylinder is now open to the air supply and
the lower side to the atmosphere.
• Thus the action is to return the piston to the neutral position.
• Thus the position of the piston is proportional to the input pressure.

Prof. S.J.Gambhire, MANET, Pune 17

Hydraulic Actuator

Prof. S.J.Gambhire, MANET, Pune 18

• Hydraulic actuators are used when large forces are required, which are
not available from pneumatic actuators using gas as the working fluid.
• Here, incompressible fluid is used to provide the pressure, which can be
made very large by adjustment of the area of the forcing piston A1, as
shown in fig.
• Let, F1 = applied piston force (N)
A1 = forcing piston area (m2)
then, the hydraulic pressure PH is given by;
PH = F1\A1 (Pascal)
• The resulting forces on the working piston is then given by;
F2 = PH * A2 (N)
where, A2 = working piston area (m2)
substituting for PH we get;
F2 = A2/A1 * F1
• Since A2 > A1, it follows that the hydraulic actuator converts a small force
F1 into an amplified force F2, with amplification factor of A2/A1.

Prof. S.J.Gambhire, MANET, Pune 19

• Pneumatic Valve Positioner
• Pneumatic valve positioner is another important component used in
process control.
• The control valve should be moved up or down, depending on the air
pressure signal (3-15 psi).
• The valve positioner can be of two types
(a) direct acting type and
(b) (b) feedback type.
• The direct acting type valve positioner is shown in Fig. A
• Here the control pressure creates a downward pressure on the diaphragm
against the spring, and the stem connected to the diaphragm moves up or
down depending on the control pressure pc.
• At equilibrium the displacement of the stem can be expressed as:
• 𝑃𝐶 A=KX
• where A is the area of the diaphragm and K is the spring constant.

Prof. S.J.Gambhire, MANET, Pune 20

• Fig. A : Pneumatic Valve Positioner

Prof. S.J.Gambhire, MANET, Pune 21

• But the major shortcoming of this type of positioner is the nonlinear
characteristics.
• Though ideally, the stem displacement is proportional to the control
pressure (from Fig. B), the effective area of the diaphragm changes as it
deflates. The spring characteristics is also not totally linear.
• Moreover, in Fig. B we have neglected the upward thrust force exerted by
the fluid.
• The change in thrust force also causes the change in performance of the
positioner.
• Besides the force exerted on the control valve is also not sufficient for
handling valves for controlling large flow.
• As a result, the use of direct acting type valve positioner is limited to low
pressure and small diameter pipelines.
• The feedback type valve positioner (Fig. B) has a pilot cylinder with which
the diaphragm is attached.
• The piston of this pilot cylinder opens or closes the air supply and vent
ports to the main cylinder whose piston is connected to the stem of the
control valve (not shown). Prof. S.J.Gambhire, MANET, Pune 22
• Fig. B : Feedback type valve positioner

Prof. S.J.Gambhire, MANET, Pune 23

• There is a mechanical link connected to the stem that adjusts the fixed
end of the spring connected to the diaphragm. This link provides the
feedback to the positioner.
• As the control pressure increases, the diaphragm moves down, so is the
piston of the pilot cylinder.
• This causes the lower chamber of the main cylinder to be connected to
the 20 psi line and the upper chamber to the vent line.
• Compressed air enters the bottom of the main cylinder and the piston
moves up.
• As the piston moves up, the feedback link compresses the spring further
and this causes the diaphragm to move back to its original position.
• The air supply and the vent ports are now closed and the piston of the
main cylinder remains at its previous position.
• The relationship between the control pressure and movement of the
stem in this case is more or less linear.
• Moreover due to presence of power cylinder, the scheme is more
suitable to position large control valves.
• Prof. S.J.Gambhire, MANET, Pune 24