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Valves and Actuators
Valves and Actuators
TRAINING MANUAL
Course EXP-MN-SI040
Revision 0
Field Operations Training
Instrumentation Maintenance
Valves and Actuators
INSTRUMENTATION MAINTENANCE
VALVES AND ACTUATORS
SUMMARY
1. OBJECTIVES ..................................................................................................................6
2. INTRODUCTION .............................................................................................................7
2.1. LOCATION IN A REGULATION LOOP.....................................................................7
2.2. DEFINITION..............................................................................................................8
2.3. ROLE OF THE VALVE..............................................................................................8
2.4. CONSTRAINTS.........................................................................................................8
2.4.1. Due to the fluid ..................................................................................................8
2.4.2. Due to the effect of the environment on the valve .............................................9
2.4.3. Due to the effect of the valve on the environment .............................................9
2.4.4. Due to the assembly conditions.........................................................................9
2.5. TECHNOLOGY OF A REGULATION VALVE .........................................................10
2.6. CHARACTERISTICS OF REGULATION VALVES .................................................12
2.6.1. Inherent flow characteristic..............................................................................12
2.6.1.1. Definition ....................................................................................................12
2.6.1.2. The linear characteristic .............................................................................12
2.6.1.3. The equal percentage characteristic ..........................................................13
2.6.1.4. The quick opening characteristic................................................................14
2.6.1.5. Inherent adjustment coefficient or rangeability ...........................................14
3. VALVE TYPES ..............................................................................................................15
3.1. LINEAR ACTION VALVE ........................................................................................15
3.1.1. Plug type valve with single-seat body..............................................................15
3.1.2. Plug type valve with double-seat body ............................................................17
3.2. CAGE VALVE .........................................................................................................19
3.3. 3-WAY VALVE ........................................................................................................21
3.4. DIAPHRAGM VALVE ..............................................................................................23
3.5. VERTICAL LIFT GATE OR GUILLOTINE VALVE...................................................24
3.6. MICRO-FLOW CONTROL VALVE WITH ADJUSTABLE Cv ..................................25
3.7. ROTARY VALVE.....................................................................................................27
3.7.1. Butterfly valve..................................................................................................27
3.7.2. Spherical plug ball valve, known simply as a "Ball valve"................................28
3.7.3. Semi-rotary valve with eccentric shutter ..........................................................30
4. TYPES OF PLUG ..........................................................................................................33
4.1. QUICK OPENING LINEAR PLUG...........................................................................34
4.2. LINEAR PLUG ........................................................................................................34
4.3. MODIFIED LINEAR PLUG ......................................................................................34
4.4. EQUAL PERCENTAGE PLUG................................................................................35
4.5. PARABOLIC PLUG .................................................................................................35
5. TYPES OF CAGE ..........................................................................................................36
5.1. QUICK OPENING CAGE ........................................................................................36
5.2. LINEAR CAGE ........................................................................................................36
5.3. EQUAL PERCENTAGE CAGE ...............................................................................37
5.4. LOW NOISE CAGE.................................................................................................37
Training Manual: EXP-MN-SI040-EN
Last Revised: 09/04/2008 Page 2 / 129
Field Operations Training
Instrumentation Maintenance
Valves and Actuators
1. OBJECTIVES
The purpose of this course is to provide a future instrument engineer with knowledge of all
the types of valves and actuators on an industrial site which has a predominantly
petroleum-related activity.
At the end of the course, the trainee should have the following knowledge concerning
valves and actuators:
2. INTRODUCTION
In a regulation loop, the final adjustment component is usually an automatic valve which,
by acting on the flow-rate of a fluid (gas or liquid), enables the measured value to be
regulated:
Pressure
Flow-rate
Level
Temperature, etc.
The automatic valve is the final component of a regulation system; it is the component that
acts directly on the process.
W Y GR
CONTROL
REGULATOR COMPONENT PROCESS
"Valve"
X
MEASURING
COMPONENT
"Sensor Transmitter"
W : Setpoint
Y : Control signal from the regulator
GR : Adjusting value
X : Measurement from the sensor-transmitter
2.2. DEFINITION
Valves are components with a variable orifice, which enable a fluid flow to be adjusted.
They are the actuators of most regulation systems, and this means that they are
significantly important components. It is for this reason that the catalogues issued by valve
manufacturers are extremely well presented and constitute the best possible
documentation on the subject.
The role of the instrument engineer is often limited to the maintenance and adjustment of
installed valves.
Sometimes, when observing the operation of regulation systems that are not performing
properly, it can be observed that the valve is operating in an abnormal manner: this almost
always occurs very close to the closing point or, conversely, the valves are too often found
to be fully open.
A regulating valve modifies a fluid flow-rate (adjustment value), as a function of the signal
from a regulator (control signal) or a transmitter, and it does this whatever the constraints
connected with the circulation of the fluid.
2.4. CONSTRAINTS
The fluid is either a liquid or a gas (or vapour), or it can be a two-phase mixture (liquid-
solid, water-steam), and these states depend on certain service conditions and the
chemical composition of the fluid.
Examples:
Flammable fluid
Viscous fluid
Pressure
Food product.
Explosive Atmosphere,
Corrosive Atmosphere,
Vibrations,
All these conditions will have a determining effect on the choice and type of valve to be
used in an operating process.
The body
The actuator
The body comprises the body of the valve with its seat, shutter, studs, etc., and the
packing gland cap.
Note: The flow running through the body is a function of the passage area, but also of the
pressure upstream of the flange.
It is the element of the valve that is connected to the pipe, and through which the fluid
flows.
Comment:
A cylinder,
An electric motor,
A servomotor: This is the name generally given to the device located above the
body, and which functions with pneumatic power.
As the cylinder, the electric motor and the servomotor are all "powered", they can be
remote controlled and still therefore be used for analog and digital regulation.
2.6.1.1. Definition
This is the law that represents the flow-rate as a function of the displacement of the plug
(or shutter), for a constant ∆P.
The flow changes linearly as a function of the signal. The characteristic is a straight line.
Equal increases in the valve signal cause equal increases in flow-rate.
The characteristic is an exponential function. Equal increases in the valve signal cause
equal increases in relative flow-rate.
This characteristic consists of a rapid increase in flow at the beginning of the opening
range, reaching approximately 80 % maximum flow for less than half the command signal.
This characteristic is very often used for safety applications with All or Nothing valves.
A regulating valve can only provide efficient adjustment within a specified flow range. This
is defined by a coefficient R.
Rangeability defines the ability of a valve to control low flow-rates. This means that a valve
with a rangeability of 100 will be capable of controlling a minimum flow-rate that is 100
times less than the maximum flow-rate.
Another way of saying this is that the adjustment range is from 1 to 100.
3. VALVE TYPES
We will begin by presenting the various types of valve body.
The size of the regulating valve body is proportional to the displacement of the shutter.
These valves are also called "standard valves". The shutter is a plug which is displaced by
the servomotor with a translational movement.
ADVANTAGES DISADVANTAGES
The position of the plug in front of the seat determines the passage area for the fluid. L
The thrust of the fluid against the plug can be very high in cases of high pressure
differentials, requiring the use of a powerful servomotor.
The figure above clearly shows how the fluid flows as it passes through a single seat body.
This provides a better view of the operation of the valve when the plug stem rises and lifts
the plug off its seat.
The forces on the shutter system tend to balance themselves out due to the fact that the
fluid attempts to open one plug and to close the other.
These weak forces improve the stability of the valve, which means that a smaller diameter
servomotor can be chosen for a valve of the same capacity.
They do not provide very good sealing when closed, due to the fact that both plugs can
never be perfectly seated on their respective seats at the same time.
The above figure shows the same fluid displacement principle as seen in a double-seat
body.
ADVANTAGES DISADVANTAGES
The forces are almost perfectly balanced Inferior sealing to that of the single seat
This is a single-seat / plug type valve which also has the advantages of the double seat /
plug valve.
Comment:
low-noise cage,
anti-cavitation cage.
ADVANTAGES DISADVANTAGES
Anti-cavitation
Anti-flash
3-way valves are designed to regulate either a fluid mixing process or a fluid bypass. It
should be particularly noted that this type of valve has a high flow capability and a low
recovery.
The flow capability is among the best of all currently-available 3-way valves. Pressure
recovery is small.
These valves are also designed to be installed with the fluid tending to open the double
plug (mixing valve) or each of the plugs (bypass valve). This configuration has the
advantage of ensuring stable operation of the valve.
The diaphragm valve is an alternative to the spherical plug ball valve. It is used as an All-
or-Nothing valve in small applications (e.g. hot water injection to clean a level sensor
flange separator, etc.).
Fs
Flexible diaphragm
FP
The force "Fs" developed by the servomotor must overcome the force "Fp" created by the
static pressure on the diaphragm.
ADVANTAGES DISADVANTAGES
ADVANTAGES
DISADVANTAGES
Figure 17: Micro-flow control valve with adjustable valve coefficient (Varipak)
Training Manual: EXP-MN-SI040-EN
Last Revised: 09/04/2008 Page 25 / 129
Field Operations Training
Instrumentation Maintenance
Valves and Actuators
To find out what the Cv of a valve is, refer to the "Valve Sizing" chapter of this course.
The shutter is a disk whose diameter is equal to the inside diameter of the duct. When
closed, the surface of this disk is perpendicular to the fluid flow direction. The variation of
the passage area is achieved by tilting this disk away from the vertical.
The stem of the shutter rotates, which is much better for the packing gland (better sealing).
This rotation is often limited to an opening angle of 60°, due to the extent of the torque
applied by the fluid.
ADVANTAGES DISADVANTAGES
This type of valve can only be manufactured for large diameters ND > 4". Considering the
surface area and shape of the shutter, it cannot be used for very high pressures. Due to
the long length of the mating surface of the butterfly on the body (which also constitutes
the seat), sealing in the closed position is difficult to obtain, and is therefore usually poor.
Also note that there is friction due to the thrust of the liquid, which presses the shutter stem
against the seal (transverse effort).
Contains a sphere or ball with a nominal diameter which is generally equal to that of the
pipe.
ADVANTAGES DISADVANTAGES
Good sealing
The actuator pushes the lever to a varying extent based on the pneumatic signal it
receives, and this causes the shaft to rotate and therefore the shutter to rotate as well.
A slight lateral play of the hub on the shaft enables the shutter to self-centre.
The extremely efficient sealing between the seat and the shutter is obtained by elastic
distortion of the shutter arms.
The slightly chamfered seat is secured inside the body by means of a threaded clamp ring.
ADVANTAGES DISADVANTAGES
Direct flow valve with a small footprint, Greater tendency to cavitate than straight
usually installed between flanges valves, but not as much as butterfly valves
4. TYPES OF PLUG
To obtain the 3 fundamental characteristics described above, we need to change the type
of plug on a valve. This plug will modify the flow of fluid passing through the valve body.
These plugs are mainly used in All-or-Nothing regulation loops and in safety systems.
These plugs are a compromise between the linear and quick opening characteristics.
These plugs are used in pressure regulation loops, and more generally in
processes where only a small proportion of the total pressure differential can
be absorbed by the valve.
These plugs are a compromise between the linear and equal percentage characteristics.
They have a linear characteristic with high flow and displacement characteristics.
5. TYPES OF CAGE
In the same way as for plugs, cage valves have different types of cage which modify the
flow characteristic.
The quick opening, linear, and equal percentage characteristics are determined by the
shape of the openings in the cage.
6. THE CAP
This part is installed on the top of the valve body, and its purpose is to provide sealing
around the plug stem.
It acts as a guide for the plug stem(s), contains the packing gland and supports the
servomotor.
The packing gland is a very widely used sealing system. Its principle of operation consists
in providing sealing by compression of several braids (packings) around the stem of the
plug by means of the packing gland rammer.
To obtain absolute sealing, a secondary boot can be joined to the plug stem. This is known
as an "extension" or an "extension boot").
The sealing boot ensures total sealing between the valve stem and the
cap. This technology is typically proposed for applications involving toxic,
flammable or explosive fluids for which any leakage could have serious
consequences for personnel and and/or the environment.
Boot
In the world of maintenance, the term "Braids" is often used when referring to gland
packings.
Packing rings: These are ready-made seals, to the diameter you need.
Braids: These are in the form of coils, and it is up to the instrument engineer to
cut them to the correct length so that it corresponds to the diameter of the
rammer.
Both types of braid shown in the figure above are the most commonly used. Graphite
braids are often used on valves in heating systems, operating at very high temperatures
and at high pressures.
But it is important to know that by constantly retightening valve packing glands, the
braids end up becoming crushed and no longer provide proper sealing.
The figure above show what happens when a valve is not properly maintained.
7. THE SERVOMOTOR
The servomotor is the component that enables the plug stem of the valve to be actuated.
The force developed by the servomotor serves two purposes:
These two criteria determine the sizing of the servomotors. The driving fluid can be air,
water, oil or gas.
The supply fluid (at 1.4 bars or 2.1 bars) is usually air, and the command pressure varies
from 0.2 bars to 1 bar. The following types of servomotor are available:
Rolling diaphragm type servomotor, principally used for rotary valves (example:
Masoneilan CAMFLEX valve),
Piston type servomotor, used in applications where very high forces are required.
The command pressure can be very high. The driving fluid can be air, water or
oil,
Electric servomotor, used for rotary valves. An electric motor is associated with a
gearbox, thus enabling very high torque values to be obtained,
7.1.1.1. Operation
On one side, the force due to the pressure in the servomotor (modulated
pressure from the regulator). It is proportional to the air pressure and to the
surface of the diaphragm (F = P x S).
On the other side, the force due to the compression of the spring which
increases as the spring is compressed.
For a given air pressure in the servomotor, the spring contracts by a length such that the
resulting force (proportional to the shortening of the spring) is equal to the corresponding
motive force.
For each pressure value, the displacement of the diaphragm is transmitted by the stem to
the plug, the displacement of which is proportional to the air pressure exerted on the
diaphragm.
For Split-Range valves (refer to the course on "the regulator and its functions"), calibration
of the valve consists in adjusting:
7.1.1.2. Description
A rubber diaphragm,
A return spring,
Diaphragm
plate
Spring
stem
Coupling with
the valve lever Spring
The rolling diaphragm type servomotor consists of a cylinder clamped in a flange by 4 BTR
screws. The rolling diaphragm is secured both to the cylinder and to the piston which is
connected to the position of the spring.
Unlike the standard servomotor in which the displacement of the diaphragm plate
assembly is small, this type of Servomotor has a large displacement.
The coupling between the servomotor and the lever of the valve consists of a small
cylinder fitted with a circlip.
The rolling diaphragm is used in more and more applications and can be found on
spherical plug ball valves and on rotary valves.
Its cost is relatively low and it is extremely easy and quick to maintain.
Piston type servomotors operate at much higher pressures than diaphragm type
servomotors.
They are capable of producing much higher forces and of operating over much longer
ranges, and can therefore overcome very high pressure differentials through the valve
body.
The two-way servomotor has the particularity of having two air inlets, because we
introduce air on one side of the piston to open the valve, and on the other side of the
piston to close the valve, which is normal because there is no return spring.
Piston type servomotors are very often associated with butterfly valves. They can be used
as All-or-Nothing valves, but they can also be used as regulating valves with an electro-
pneumatic positioning device.
Generally speaking, when a piston type servomotor is used as a regulating valve, this is
because the operating conditions involve very high pressures in large diameter pipes.
They are similar to diaphragm type servomotors in that they can be installed either on a
linear displacement valve or on an angular displacement (rotary) valve.
7.2.1. Constitution
A hydraulic pump,
A hydraulic reservoir,
A valve control,
This type of servomotor is used in very high pressure processes, in which the operating
pressure can be up to about a hundred bars. It can also be used in low-pressure systems,
but the valve opening takes longer because the hydraulic system has a lot of torque.
In the same way as for the piston type servomotor, the hydraulic servomotor can be a one-
way or a two-way device.
7.2.2. Operation
The advantage of this actuator is that we only need an electrical signal to "rotate" the
motor, so the associated valve can either open or close.
This type of motor is reversible because it rotates in both directions. It is equipped with a
gearbox which enables the torque to be reduced, in order to prevent the electric motor
from applying too much force on its rack.
Training Manual: EXP-MN-SI040-EN
Last Revised: 09/04/2008 Page 51 / 129
Field Operations Training
Instrumentation Maintenance
Valves and Actuators
A solenoid is a coil of electric wire wound around a cylinder in with all the turns in
contact with each other. The induction of the magnetic field generated by a solenoid
is proportional to the number of turns and to the intensity of the current passing
through it, and is inversely proportional to its length.
When an electrical signal is injected into the solenoid, this generates a magnetic field
which will act on the spring and cause the diaphragm to distort.
Depending on whether or not the diaphragm is distorted, the plug of the valve will be either
open or closed.
The direction of action of the valve body depends on the shutter system (plug + seat).
Direct action valve body: extension of the plug stem closes the shutter system.
You will have noticed that the figure on the left shows a single-seat valve body,
and that the figure on the right shows a double-seat body.
Reverse action valve body: extension of the plug stem opens the shutter
system.
Comment:
Some valve bodies are reversible, in other words the action of the plug can easily be
reversed by simple disassembly.
If an air failure occurs, the counter-spring causes the servomotor to move to an extreme
position so that the shutter can move to a completely open or a completely closed position.
These types of servomotor therefore do not pose any particular problem when it comes to
complying with the specification, for direct or reverse action servomotors.
Direct positioning device: When the input signal increases, the output signal
increases.
Reverse positioning device: When the input signal increases, the output signal
decreases.
If an air failure occurs, the piston takes any position depending on the force exerted by the
fluid on the shutter of the valve.
In order to force the position of the shutter, it is therefore necessary to provide a device
comprising both a reserve of compressed air and switching components which enable the
valve to be moved to the selected position in case of failure of the distribution system air
supply.
When there is no more pressure on the servomotor, the spring returns the valve to its open
or closed position, as defined by the construction of the device.
A "Fail Closed" valve, i.e. one which is closed when there is a lack of air, closes
when there is no longer any pressure on the servomotor.
A "Fail Open" valve, i.e. one which is open when there is a lack of air, opens
when there is no longer any pressure on the servomotor.
The choice depends essentially on the safety conditions for the process.
Comment: When the positioning device is electro-pneumatic, the chances are it will be of
the direct type.
8. VALVE ACCESSORIES
The positioning device is a device used to slave the displacement of the plug to the control
signal from the regulator.
For the regulation system to operate correctly, it is essential for the displacement of the
plug to remain precisely proportional to the value of the regulator output signal.
However, certain interference forces can hinder the movement of the plug:
Thrust exerted by the fluid (particularly in the case of single seat plugs)
These forces depend on the operating conditions: severe conditions → High forces
It is therefore necessary, in order to obtain a plug position that corresponds to the value of
the control signal, to complete the regulation system by a positioning device.
There are 3 types of positioning device that can be adapted to a regulating valve:
8.1.1.1. Features
The function of the pneumatic positioning device is to ensure linear or other slaving
between the displacement of the valve and a pneumatic signal output by a regulator.
It also has another function, which is to modify the natural characteristic of a valve by
means of a cam whose profile depends on the required characteristic.
It can also be configured for the "cascaded" (Split-Range) control of several valves, and
can be used with an augmented pneumatic supply enabling it to operate the valves under
higher differential service pressures.
It is also possible to reverse the direction of action of the valves by means of the
positioning device.
8.1.1.2. Constitution
The profiled cam: this is the intermediate component between the reaction
device, the valve actuator and the spring of the positioning device. Its profile
determines the relationship between the position of the shutter of the valve and
the signal output by the regulator. "Linear" or "equal percentage" characteristics
are available by selecting the appropriate sector of the cam.
The controller: this is a small 3-way distributor valve. The valve adjusts the
compressed air flow-rates from the supply to the outlet on the actuator, and from
the outlet to the exhaust orifice. The position of this valve is controlled by the
diaphragm, and determines the discharge pressure of the actuator. The action of
the pneumatic positioning device can be reversed by reversing the supply and
exhaust connections and by changing the cam sector and the orientation of the
lever.
The return spring: this enables the slide valve of the controller to slide in the
distributor valve.
The reaction spring: this enables the cam to be rotated by varying the rotation
of the lever. This variation is due to the pressure exerted on the diaphragm.
The pneumatic positioning device is based on the principle of a force equilibrium device:
the pressure of a pneumatic signal applied to diaphragm opposes the force of a reaction
spring.
In the state of equilibrium, if the pneumatic signal varies, the diaphragm assembly moves.
The movement drives the slide valve of the controller, which is pressed by the return
spring.
The displacement of the slide valve alternately sets the outlet system into
communication with the supply system or with the exhaust system, thus modifying the
pressure applied on the actuator.
The cam transmits the displacement of the valve shutter to the reaction spring.
The valve shutter continues its movement until the force of the spring precisely balances
that developed by the pressure of the pneumatic signal on the diaphragm. In this state of
equilibrium, the position of the valve shutter in front of the seat corresponds to that ordered
by the signal from the regulator.
Output signal
to actuator
Figure 64: View of the cam with and its reaction spring
We have already seen, in the features of the positioning device, that the cam can change
the characteristic of the valve - the following table gives the cam positions and cam lever
orientations of a MASONEILAN CAMFLEX II or VARIMAX:
8.1.1.4. Faults
The main faults you are liable to encounter on this type of positioning device are:
The exhaust orifice is blocked, so the valve will no longer regulate and stays fixed
in a certain position,
The slide valve of the controller is blocked; the air in the positioning device
sometimes condenses and produces a little humidity in the slide valve, causing
the slide valve to seize up.
Despite these various minor failures that can occur, the mechanism of this pneumatic
positioning device makes it a very robust device that requires little maintenance.
8.1.2.1. Constitution
A cam,
A return spring,
A controller: this is an amplifier relay which will amplify the output signal from
the nozzle to the actuator.
The principle of operation is almost identical to that of the pneumatic positioning device.
In actual fact, we have retained the pneumatic valve positioning system with the cam and
its lever, but a nozzle and flapper with an electromagnet have been added to enable the
pneumatic signal of the regulator to be replaced by an electrical signal (4-20 mA).
Here, the controller is not a distributor with its slide valve and push-rod, but an amplifier
relay with a diaphragm.
In this case, the signal from the regulator is no longer a pneumatic signal (0.2 to 1 bar), but
an electrical signal (4-20 mA).
The electrical signal (4-20 mA) will pass through the solenoid, and this will move the
flapper. This results in a change in the nozzle output pressure until the reaction of the ball
located at the end of the nozzle balances out the new force applied on the lever.
The more the electrical signal increases, the closer the flapper will move to the nozzle: the
nozzle output signal to the actuator will also increase and therefore tend to open the valve.
We can also change the direction of action of the positioning device, for which it is
necessary to:
Reverse the wires of the solenoid on the terminal strip of the positioning device.
Figure 71: Solenoid wire reversal to change the direction of action of the positioning device
A great deal of care must be taken to avoid blocking the rocker with the
wires of the solenoid, otherwise the valve will operate in
"ALL-OR-NOTHING" mode, in other words either wide open or
completely closed. The reason I am telling you this is that it happened
to me once, by mistake.
8.1.2.3. Faults
Solenoid jammed in the core. This is due to humidity in the positioning device and
distortion of the solenoid,
Clogged nozzle → The nozzle must imperatively be cleaned with compressed air,
The intelligent positioning device is the latest version of the positioning device, which is
becoming more and more widely used.
8.1.3.1. Constitution
A nozzle-flapper system,
An electromagnet: this is the solenoid with its core, which enables the flapper to
be tilted to varying degrees with respect to the nozzle thanks to the magnetic field
created by the electric current passing through it,
A digital display: it will enable the positioning device to be configured and will
display either the fault diagnosis or all the measurement information of the
positioning device.
This type of positioning device is always supplied at a pressure of 1.4 bars, through a
pressure reducing filter.
The electrical signal from the regulator is always a current signal of 4-20mA.
The central processing unit, or CPU, is the functional centre of the positioning device. The
mechanical and pneumatic components provide only secondary functions.
The input signal (4-20 mA) and the position measurement signal are cyclically checked by
the CPU and sent to an analog-to-digital converter, thus enabling rapid and precise data
processing.
The general program also comprises a self-adjustment routine to automatically adjust the
device on the valve actuator, and also an adaptive self-regulation mode which ensures
optimum control and monitoring of the position irrespective of the operating conditions
(supply pressure variation, for example).
The servomotor is controlled by an I/P converter and a 3-way valve (distributor valve). The
electrical signal from the CPU is proportionally converted into a pneumatic signal which
adjusts the 3-way valve. The passage area is constantly modified to inflate or empty the
servomotor proportionally with respect to the signal.
When the valve position is reached, the 3-way valve is in its neutral position (the air flow is
practically zero).
To make it easier for you to understand the operation, bear in mind that the positioning
device operates as a regulator (refer to the course on "the regulator and its functions").
The 4-20 mA input signal is the setpoint, and the position measurement performed by a
position sensor is the measurement. The CPU compares these two values and sends a
proportional electrical signal to the electromagnet, which will provide the means of acting
on the control component (3-way valve) in order to establish measurement = setpoint.
The standard positioning device is equipped with a local keypad (4 keys) and a 2-line
display. This keypad is used for local configuration and for monitoring of the parameters in
operation. Configuration, commissioning and observation can also be carried out remotely,
via the communication port (FSK module), using a computer.
You can connect to the device either locally or anywhere on the 4-20 mA link.
It can be installed on linear or rotary valves, and this is also a simple matter of configuring
the device.
8.1.3.3. Faults
This type of positioning device often suffers electronic failures, which means that
maintenance is a simple matter of replacement, so several intelligent positioning devices
must be kept in stock, as the devices can be considered as "disposable".
The I/P converter is used in all electronic loops for which the actuator is pneumatic, or for
passing through explosive areas for example (refer to the course on equipment in high risk
areas). It converts standardised electrical signals into standardised pneumatic signals.
The electro-pneumatic converter receives a 4-20 mA electrical signal and converts it into a
200-1000 mbar (0.2-1 bar) pneumatic signal.
The converter is also supplied by an air pressure of 1.4 bars (1400 mbars).
The difference between the I/P converter and the electro-pneumatic positioning device is
that there is no valve position in this case.
The seal packing is lubricated in order to facilitate the displacement of the shutter stem
and to maintain the braids of the packing gland so that they do not deteriorate too quickly.
Position sensors are widely used on All-or-Nothing valves to show whether there are any
safety valve discrepancies.
The contacts of these position sensors can be Normally Open (NO) or Normally Closed
(NC).
8.4.1. Microswitch
This type of position switch is used as a safety device on valves, to provide the operator
with an alarm in the case of a valve discrepancy.
Valve open
Valve closed
Inductive sensors use the physical effect of the change of state of a resonant circuit,
caused by eddy current losses in conductive parts.
An LC oscillator circuit generates an alternating high frequency field which is radiated from
the active surface of the sensor.
Capacitive sensors are used for the no-contact detection of objects made of any material.
Unlike inductive sensors, which can only detect metallic objects, capacitive sensors are
capable of detecting non-metallic objects. Typical applications can be found in the
following industries: wood, paper, glass, plastic, food processing and chemicals.
A solenoid
Reminder:
The two-way actuator is a dual-piston servomotor, so it is necessary to send air onto one
of the pistons whenever we want to open or close a valve.
8.6.1.1. Purpose
The chambers of a valve actuator, when operating, must be alternately connected to the
pressure and to the exhaust.
We are obviously not going to swap the pipe connections around to achieve this.
The distributor valve that is schematically represented here will be used to supply a two-
way actuator (since two ducts have been provided to supply the valve actuator).
A distributor valve will be identified by the number of pipes that can be connected to it (this
is stated as the number of orifices) and the number of positions that the slide valve can
occupy.
4 orifices:
one supply,
one exhaust,
one connection to the front chamber,
one connection to the rear chamber;
and 2 positions.
8.6.1.3. Diagrams
The ends of the arrows are located opposite the pipes that
lead to the chambers of the actuator, the air supply and the
exhaust.
Electrical control
Push-button control
Pneumatic control
Push-button control
Spring control
If the distributor valve has a spring control, it is monostable. This means that only the
position obtained through the action of the spring is stable: in the absence of an external
control signal, the slide valve automatically goes to the spring position.
If the distributor valve has two control devices of the same type, it is bistable. This means
that both positions are stable positions: in the absence of an external control signal, the
slide valve does not move and remains in its current position.
The electrical control will be implemented by means of a solenoid, which will be located on
the pneumatic distributor valve.
Seal
Figure 104: Connectors used for the electrical connection of the solenoid
For everything that concerns the electrical connection details of each instrumentation
accessory, please refer to the "Instrumentation Accessories course".
Manual controls are installed on the servomotor, and their purpose is to enable the valve
to be operated manually in certain cases:
In case of emergency.
The manual control installed on the side of a servomotor can be used as a limit stop in
both directions.
9. MAINTENANCE
Before doing anything else, it is absolutely essential to check that the valve is no
longer under pressure.
Check the surface condition of the braid recess and of the control stem (no
scratches, marks, etc.)
Carefully clean the inside of the packing gland (blow clean with compressed air)
Once this operation has been carried out, it is necessary to repack the packing gland. This
is done by proceeding as follows:
Use the rammer to help press the braids into the recess
When installing the last ring, place the rammer in contact with the braids and
manually tighten the nuts.
After completing this tightening phase, the control stem must turn without any
more effort than before installing the braids.
Gently tighten the rammer with a wrench until a slight resistance is felt when
operating the stem.
To obtain this, wind the braid around the shaft liner (or around Example of a straight cut
a bar of the same diameter) to form a tight helix. (Take the
necessary precautions to avoid scoring the liner).
Experience has shown that an oblique cut is preferable to a straight cut. This makes it
easier to install the braid.
To obtain optimum sealing, it is necessary to tighten the rammer to between 2 and 5 times
the service pressure, depending on whether the fluid is a liquid or a gas.
It is essential to avoid jamming the rammer, so the braid must me tightened evenly and in
controlled manner.
The calibration of an I/P converter is quite simply the reverse of the adjustment of a
pressure transmitter.
To do this, we inject a 4-20 mA signal into the converter by means of a 4-20 mA current
generator (a tool which is very widely used by instrument engineers).
We then use a pressure gauge to check the output signal of the converter (0.2-1 bar). The
converter output signal must be linearly proportional to its input signal (4-20 mA).
If you see that the zero or the scale of the converter is offset, two adjusting screws are
provided for this purpose on an I/P converter.
You can also select the fail-safe state of the converter to be either high or low, by means
of the Mode switch. The same applies to the high or low scale, with the Lo-Hi Span
selection switch.
Connect the signal conductors. Connect the wires of the solenoid to the terminals
of the circuit board,
Adjust the signal you wish to inject using your 4-20 mA to 12 mA generator,
Adjust the supply pressure to 1.4 bars for a pneumatic output signal of
0.2 - 1 bar,
Turn the screw of the zero spring (52) to obtain the output value that corresponds
to a 12 mA input signal, i.e. up to 0.6 bars,
And finally, check the pneumatic output signal for 4 and 20 mA, which
corresponds to 0.2 bars and 1 bar.
If all the values are correct, you have finished the zero adjustment.
With the supply pressure adjusted to 1.4 bars, record the output pressure when
the electrical signal is it at its minimum value (4 mA),
Increase the electrical signal to its maximum value (20 mA) and record the output
pressure. A variation of the electrical signal for the min. and max (from 4 to
20 mA) should cause an output pressure variation of 0.8 bars if the scale is
0.2-1 bar,
If the pressure variation is different, pull clear the flapper (24) located at the rear
of the converter, remove the plug with an Allen wrench and then loosen and
unscrew the clamping screw by a few turns,
Turn the scale adjustment screw in either direction until the total variation of the
electrical signal causes the required total output pressure variation. To increase
the pressure variation amplitude, turn the adjustment screw clockwise. To reduce
the amplitude, turn the screw counter-clockwise,
Unscrew the screws (44) and (45) to release the solenoid (40) from the rocker,
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Valves and Actuators
Lightly secure the new solenoid on the rocker with the screws (44) and (45); do
not tighten the screws. The stop screw (44) must not protrude beyond the inside
face of the solenoid,
Secure the rocker onto the magnet with the flexible strips and screws, and then
align the rocker according to the instructions provided in the following chapter.
Insert a 1/8" cylindrical pin in the alignment holes of the solenoid, the rocker and
the magnet, and place a shim with a height of 5/32" and a maximum width of
1 mm on the magnet, between the rocker and the solenoid.
Tighten the two bottom screws (42) of the inner flexible strip on the rocker, and
the two bottom screws of the outer flexible strip on the magnet.
Remove the flapper from the rocker. Reinstall the complete mechanism in the
case. Locate the zero spring support (39) and tighten the two screws (4).
Apply slight pressure on the rocker over the solenoid and adjust the stop screw
(44) until the rocker is parallel to the sealing faces of the case and cover. Whilst
maintaining the rocker in this position, tighten the other four screws of the flexible
strips,
Tighten the screw of the solenoid (45) and remove the alignment pins,
In case of anomaly of the I/P positioning device, there are two fundamental systems that
need to be checked:
With a supply at 1.4 bars, check that the output signal drops to less than 0.1 bar
when the flapper is moved slightly away from the nozzle,
Apply a slight pressure on the flapper in order to close off the nozzle, and check
that the output signal reaches 1.4 bars,
If these results are not obtained, clean the calibrated orifice (59) by pressing its
unblocking device. Check the cleanness of the nozzle (16) and check that ball is
still in position. Check that the calibrated orifice (59) is correctly screwed into the
body of the controller. If the device continues to operate incorrectly, it will be
necessary to disassemble the controller,
If operation is irregular, check that there are no foreign particles lodged inside the
solenoid and the magnet.
Connect the ohmmeter to the terminals of the converter circuit and check the
resistance of the circuit; you will find a small table giving the nominal value of the
resistance on the following page.
Disconnect one of the wires from the solenoid to the circuit card of the converter
and connect it to one of the wires of the ohmmeter. Connect the other wire of the
ohmmeter to the wire of the solenoid that is still connected. The measured value
of the resistance of the solenoid must correspond approximately to the value
given in the following table.
If the measured resistance of the solenoid is approximately correct, but if the total
resistance Th is not, replace the circuit card (15). If the measured resistance of
the solenoid is incorrect, replace the solenoid (40).
Connect one of the ohmmeter wires to the solenoid stop (44), and the other to the
disconnected wire of the solenoid in order to measure its insulance. If the
resistance indicated on the ohmmeter is not infinite, replace the solenoid.
The calibrated orifice (59) is used for the passage of the air supply to the nozzle system. A
push-button, extended by a metal wire, enables the orifice to be unblocked if necessary.
The complete calibrated orifice assembly can be removed without disassembling the
controller.
9.3.3.2. Controller
Remove the four screws securing the controller onto the body of the positioning
device. Separate the complete controller,
Remove the calibrated orifice and the spring retaining plug, and then remove the
plug and its spring,
Remove the six assembly screws in order to release the other components of the
controller,
Clean the parts with a clean soft cloth; if there are traces of oil or grease, use a
solvent (except on the diaphragm and the seals). Blow through the orifices and
ducts of this distributor valve (controller) with compressed air.
Reassembly
Insert two assembly screws into the two diametrically opposite holes in the
bottom of the controller,
Onto these parts, successively fit the diaphragm assembly, the intermediate
block and the seal,
Offer this assembly onto the body of the controller after introducing the spring of
the diaphragm into the latter. Check the correct installation and centring of all the
parts,
Insert the plug and its spring. Tighten the spring retaining plug and also the
calibrated orifice,
Solenoid
Circuit card
Cam
Centre and press the diaphragm onto piston. Smear the outside face of the
diaphragm with talcum powder or grease,
Roll the diaphragm inside the spring chamber, until the ridge fits into its recess at
the entry to the spring chamber.
Gently and evenly press the ridge so that all the
adhesive-coated parts stick. Check that the
diaphragm rolled between the piston and the spring
chamber does not have any abnormal creases or
pinches in it.
10. TROUBLESHOOTING
10.1.2. Cavitation
When the static pressure in the fluid path decreases and reaches the value of the vapour
tension of the liquid at the flow temperature, the cavitation phenomenon occurs (small
vapour bubbles form in the liquid, curve 2).
When the static pressure increases again (reduction of the velocity due to widening of the
fluid path), the vapour bubbles condense and implode.
High-frequency vibrations which cause all the hardware of the valve and its
accessories to work loose;
Rapid destruction of the plug, the seat and the body, by removal of metal
particles. The surfaces that are subjected to the cavitation phenomena have a
grainy surface;
10.1.3. Vaporisation
If the static pressure downstream of the valve is low (high pressure differential in the
valve), the gas bubble implosion process does not occur: the bubbles remain present in
the fluid path, which results in the vaporisation phenomenon (curve 3).
Noise, although the sound level is not as high as that caused by cavitation;
Mechanical damage to the plug, the seat and the body, due to the high-velocity
flow of a gas and liquid mixture.
The flow coefficient Cv, used for the first time by Masoneilan in 1944, rapidly became the
universal reference for measuring the flow of fluid through a valve. This is because this
coefficient is so practical that it is now almost always used in calculations for the sizing of
valves or to determine the flow-rates passing through them.
As the basic idea to state the flow capabilities of a valve under precise conditions is of
American origin, some manufacturers give the water flow-rate in "gallons per minute" with
a ∆P of 1 PSI (valve fully open).
This specific flow-rate is called: The Cv of the valve (Flow coefficient of the valve).
Manufacturer calculation manuals state the methods for calculating the Cv, for liquids,
gases and vapours, under the most varied conditions.
These, and more generally the calculations used in valve sizing and adjustment, are often
very complex.
d
Cv = Q
ΔP
Where:
Note:
The Cv is a size reference that the technician can use to quickly and accurately determine
the size of a restriction based on known values of the flow-rate, the pressure, and any
other associated parameters; this is furthermore applicable to any fluid. The Cv is
proportional to the passage area between the seat and the plug.
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Valves and Actuators
The Cv also depends on the internal profile of the valve, and on the type of flow in the
valve.
For us technicians, it is actually easier to work with ∆P values in bars and flow-rates in
m3/h.
So the flow factor or Kv is the Cv of a valve, except that we use metric units.
Kv = 1.16 / Cv
For liquids:
Q: flow-rate in m3/h
D: density
ΔP: pressure differential in bars
Q d .T
For gases: Cv =
295 ΔP(P1 + P2 )
Note:
The formulae mentioned above are for non-critical flows.
Volumetric flow:
Gf q Gf
Cv = q Cv =
ΔP Cf ΔPs
Mass flow:
W W
Cv = Cv =
500 G f ΔP 500C f G f ΔPs
⎛ P ⎞
ΔPs = P1 − ⎜⎜ 0,96 − 0,287 V ⎟⎟ PV
⎝ PC ⎠
Volumetric flow:
Gf 1,16q G f
Cv = 1,16q Cv =
ΔP Cf ΔPs
Mass flow:
1,16W 1,16W
Cv = Cv =
G f ΔP C f G f ΔPs
⎛ P ⎞
ΔPs = P1 − ⎜ 0,96 − 0,287 V ⎟ PV
⎜ PC ⎟⎠
⎝
But as a simplification, if PV < 0.5 P1; ΔPS = P1 - PV
CV: Flow coefficient
Cf: Pressure recovery factor from the liquid in a regulating valve without adjacent unions
Gf: Density at the temperature of the flow, calculated with respect to water (1 at 15.6 °C
P1: Absolute upstream pressure (bars abs)
P2: Absolute downstream pressure (bars abs)
PC: Absolute critical thermodynamic pressure (bars abs)
PV: Vapour tension of the liquid at the upstream temperature (bars abs)
ΔP: Pressure differential P1 – P2 (bar)
q: Volumetric flow of the liquid (m³/h)
W: Mass flow of the liquid (t/h)
Q GTZ
Volumetric flow for gas: CV =
(
834C f P1 y − 0.148 y 3 )
W Z
Mass flow for gas: CV =
(
2.8C f P1 G f y − 0.148 y 3 )
W
Saturated steam: CV =
(
1.83C f P1 y − 0.148 y 3 )
W (1 + 0.0007Tsh )
Superheated steam: CV =
(
1.83C f P1 y − 0.148 y 3 )
Where, for 77000 valves, LO-DB cartridges and relief plates, and for two-stage 41000
1.40 ΔP
valves and 72000 valves: y =
Cf P1
1.36 ΔP
Where, for all other valves: y = (maximum value = 1.50, at this value
Cf P1
y - 0.148 y³ = 1.0)
Q GTZ
Volumetric flow for gas: CV =
(
257C f P1 y − 0.148 y 3 )
54.5W Z
Mass flow pour gas: CV =
(
C f P1 G f y − 0.148 y 3 )
83.7W
Saturated steam: CV =
(
C f P1 y − 0.148 y 3 )
83.7(1 + 0.00126Tsh )W
Superheated steam: CV =
(
C f P1 y − 0.148 y 3 )
Where, for 77000 valves, LO-DB cartridges and relief plates, and for two-stage 41000
1.40 ΔP
valves and 72000 valves: y =
Cf P1
1.36 ΔP
Where, for all other valves: y = (maximum value = 1.50, at this value
Cf P1
y - 0.148 y³ = 1.0)
Qeq = Q1 + Q2
Qeq = Q1 = Q2
After calculating the Cv, the choice of valve from the manufacturer's catalogue can lead to
a valve with a diameter less than that of the pipe. In this case, the valve is installed
between convergent and divergent pipe sections.
This creates an additional pressure differential, which must be taken into account in the
calculation of the valve.
It is also necessary to take the material of the pipe into account, and to choose a valve
made of the same material (e.g. Stainless Steel 316, Carbon steel, etc.).
The process conditions will enable you to choose the type of valve body.
The safety conditions will enable you to know the fail-safe position of the valve (FAIL
CLOSED or FAIL OPEN) and whether or not you add limit switches to it.
These are valves which have an emergency decompression function, releasing the fluid to
the torch of the installations.
They are mainly used on compressors, on VHP reservoirs and on gas treatment units.
These valves are present in the safety process panels, and are ordered to close when the
bar is tripped.
These valves are reopened locally - on a pneumatic or hydraulic cabinet -, once the
console operator has identified the fault, reset the safety process panel and given the
authorisation to reopen from the console.
They are necessarily of the FAIL CLOSED type. They are often two-way valves with an air
reserve.
They do not have a shut-off function, and they are not present on the safety process
panels.
These are fluid routing valves, and are mainly used on the production / test manifolds of
wells, on pump discharges and on chemical line selectors.
SDVs: Shut-Down Valves. Safety level PPSD, EPSD and higher, sometimes TPSD
These valves have a safety shut-off function. They are present on the safety process
panels and are ordered to close when the bar trips. (Note that some SDVs can be closed
by the operating personnel in case of TPSD).
These valves are then reopened from the console*, once the operator has identified the
fault and reset the safety process panel.
These valves are mainly found on the inlets / outlets of reservoirs and on machine intakes.
These valves are of the FAIL CLOSED type (except for the test separator bypass valve,
which is of the FO type).
These are SDV type valves on well-head tubings, and are also called master valves.
SCSSVs: Surface Controlled Sub-Surface Safety Valves. Safety level ESD, GSSD
These are ESDV type valves on well-bottom tubings, and are also called bottom valves.
They are controlled from the surface by high pressure hydraulic lines (up to 500 bars), in
order not to remain blocked open by the pressure of the deposit in case of leakage.
13. APPENDICES
Lengths
mm 0.10 cm inches 25.40 mm
Surfaces
mm² 0.010 cm² sq. inches 645.2 mm²
mm² 1.076 10-5 sq. feet sq. inches 0.00694 sq. feet
Flow-rates
us gall / min GPM 3.785 l / min cubic feet / hr 0.1247 gpm
us gallons / min 0.133 cubic feet / min cubic feet / hr 0.472 l / min
us gallons / min 8.021 cubic feet / hr cubic feet / hr 0.01667 cubic feet / min
Speeds
feet / sec 60 feet / min m/s 3.280 feet/sec
Masses
pounds 0.0005 short ton kg 2.205 pounds
pounds / sq.inch 51.71 torr (mm Hg 0 °c) kg / cm² 735.6 torr (mm Hg)
atmosphere 760.0 torr (mm Hg) kPa 7.501 torr (mm Hg)
bar 75.01 cm Hg
Acetic acid
841 58.0 612 322 4.15
CH3-CO-OH
Acetone
691 47.6 455 235
CH3-CO-CH3
Acetylene
911 62.9 97 36 1.26
C2H2
Air
547 37.8 -222 -141 1.40
O2+N2
Ammonia
1638 113.0 270 132 1.33
NH3
Argon
705 48.6 -188 -122 1.67
A
Benzene
701 48.4 552 289 1.12
C6H6
Butane
529 36.5 307 153 1.09
C4H10
Carbon dioxide
1072 74.0 88 31 1.30
CO2
Carbon monoxide
514 35.5 -218 -139 1.40
CO
Carbon tetrachloride
661 45.6 541 283
CCl4
Chlorine
1118 77.0 291 144 1.36
Cl2
Ethane
717 49.5 90 32 1.22
C2H6
Ethyl alcohol
927 64.0 469 243 1.13
C2H5OH
Ethylene
742 51.2 50 10 1.26
Ch2=CH2
Ether
522 36.0 383 195
C2H5-O-C2H5
Fluorine
367 25.3 -247 -155 1.36
F2
Helium
33.2 2.29 -450 -268 1.66
He
Heptane
394 27.2 513 267
C7H16
Hydrogen
188 13.0 -400 -240 1.41
H2
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Hydrochloric acid
1199 82.6 124 51 1.41
HCl
Isobutane
544 37.5 273 134 1.10
(CH3)CH-CH3
Isopropyl alcohol
779 53.7 455 235
CH3-CHOH-CH3
Methane
673 46.4 -117 -83 1.31
CH4
Methyl alcohol
1156 79.6 464 240 1.20
H-CH2OH
Nitrogen
492 34.0 -233 -147 1.40
N2
Nitrous oxide
1054 72.7 99 37 1.30
N2O
Octane
362 25.0 565 296 1.05
CH-(CH2)6-CH3
Oxygen
730 50.4 -182 -119 1.40
O2
Pentane
485 33.5 387 197 1.07
C5H12
Phenol
889 61.3 786 419
C6H5OH
Phosgene
723 56.7 360 182
COCl2
Propane
617 42.6 207 97 1.13
C3H8
Propylene
661 45.6 198 92 1.15
CH2=CH-CH3
Refrigerant 12
582 40.1 234 112 1.14
CCl2F2
Refrigerant 22
713 49.2 207 97 1.18
CHClF2
Sulphur dioxide
1142 78.8 315 157 1.29
SO2
Water
3206 221.0 705 374 1.32
H2O
Table 11: Critical pressure and critical temperature of a few selected materials
Acetic acid
65.7 1052.4 66.1
CH3-CO-OH
Acetone
49.4 791.3 58.1
CH3-CO-CH3
Acetylene
0.069 1.11 26.0
C2H2
Air
0.0764 1.223 29.0
O2+N2
Ammonia
0.045 0.72 17.0
NH3
Argon
0.105 1.68 39.9
A
Benzene
54.6 874.5 78.1
C6H6
Butane
0.154 2.47 58.1
C4H10
Carbon dioxide
0.117 1.87 44.0
CO2
Carbon monoxide
0.074 1.19 28.0
CO
Carbon tetrachloride
99.5 1593.9 153.8
CCl4
Chlorine
0.190 3.04 70.9
Cl2
Ethane
0.080 1.28 30.1
C2H6
Ethyl alcohol
49.52 793.3 46.1
C2H5OH
Ethylene
0.074 1.19 28.1
Ch2=CH2
Ether
44.9 719.3 74.1
C2H5-O-C2H5
Fluorine
0.097 1.55 38.0
F2
Helium
0.011 0.18 4.0
He
Heptane
42.6 682.4 100.2
C7H16
Hydrogen
0.005 0.08 2.02
H2
Hydrochloric acid
0.097 1.55 36.5
HCl
Isobutane
0.154 2.47 58.1
(CH3)CH-CH3
Isopropyl alcohol
49.23 788.6 60.1
CH3-CHOH-CH3
Methane
0.042 0.67 16.0
CH4
Methyl alcohol
49.66 795.5 32.0
H-CH2OH
Nitrogen
0.074 1.19 28.0
N2
Nitrous oxide
0.117 1.87 44.0
N2O
Octane
43.8 701.6 114.2
CH-(CH2)6-CH3
Oxygen
0.084 1.35 32.0
O2
Pentane
38.9 623.1 72.2
C5H12
Phenol
66.5 1065.3 94.1
C6H5OH
Phosgene
0.108 1.73 98.9
COCl2
Propane
0.117 1.87 44.1
C3H8
Propylene
0.111 1.78 42.1
CH2=CH-CH3
Refrigerant 12
0.320 5.13 120.9
CCl2F2
Refrigerant 22
0.228 3.65 86.5
CHClF2
Sulphur dioxide
0.173 2.77 64.1
SO2
Water
62.34 998.6 18.0
H2O
Table 12: Mass volume and molar masse of a few selected materials
14. EXERCISES
1. Which item is the Packing gland rammer?
Item 5
Item 6
2
Item 7 1
Item 1 5
6
Item 4
7
8
Item 8 9
Item 9
10
Item 3
Item 2
Rotary
Linear
Gravitation
Pressure differential
Cavitation
A positioning device
An electrovalve
An I/P converter
7 bars
3 PSI
To convert an electrical signal (4-20 mA) into a pneumatic signal (0.2 - 1 bar)
Both
A linear valve
A piston valve
A rotary valve
Tends to close it
Tends to open it
Is direct
Both
Fail Open
Fail Closed
15. FIGURES
Figure 1: Location of the "regulating valve" in the regulation loop .......................................7
Figure 2: Technology of a regulating valve ........................................................................10
Figure 3: The two assemblies of a regulating valve ...........................................................11
Figure 4: Linear flow characteristic ....................................................................................13
Figure 5: Equal percentage flow characteristic ..................................................................13
Figure 6: Quick opening flow characteristic .......................................................................14
Figure 7: Fluid displacement in a single-seat body ............................................................15
Figure 8: Single-seat body .................................................................................................16
Figure 9: Double-seat body................................................................................................17
Figure 10: Fluid displacement in a double-seat body.........................................................18
Figure 11: Cage valve........................................................................................................19
Figure 12: 3-way mixing valve ...........................................................................................21
Figure 13: 3-way bypass valve ..........................................................................................22
Figure 14: Diaphragm valve...............................................................................................23
Figure 15: Functional diagram of the diaphragm valve ......................................................23
Figure 16: Guillotine valve .................................................................................................24
Figure 17: Micro-flow control valve with adjustable valve coefficient (Varipak)..................25
Figure 18: Example of a micro-flow valve ..........................................................................26
Figure 19: Adjustment of the Cv ........................................................................................26
Figure 20: Butterfly valve ...................................................................................................27
Figure 21: Ball valve ..........................................................................................................28
Figure 22: Example of a ball valve.....................................................................................29
Figure 23: Valve with eccentric spherical shutter...............................................................30
Figure 24: Cross-sectional view of the eccentric spherical shutter ....................................31
Figure 25: Functional diagram of the eccentric spherical shutter valve .............................31
Figure 26: Different plugs and their flow characteristics ....................................................33
Figure 27: Quick opening plug ...........................................................................................34
Figure 28: Linear plug ........................................................................................................34
Figure 29: Modified linear plug...........................................................................................34
Figure 30: Equal percentage plug......................................................................................35
Figure 31: Equal percentage plug turned with a Vee-shaped aperture..............................35
Figure 32: Parabolic plug ...................................................................................................35
Figure 33: Quick opening cage ..........................................................................................36
Figure 34: Linear cage .......................................................................................................36
Figure 35: Equal percentage cage.....................................................................................37
Figure 36: Low noise cage.................................................................................................37
Figure 37: Diagram of valve cap ........................................................................................38
Figure 38: Packing gland of a valve...................................................................................39
Figure 39: Sealing boot......................................................................................................39
Figure 40: Graphite and PTFE packing rings.....................................................................40
Figure 41: Examples of graphite and PTFE braids ............................................................40
Figure 42: Poor sealing, leakage from the packing gland ..................................................41
Figure 43: Diaphragm type servomotor..............................................................................43
Figure 44: Simplified diagram of a diaphragm type servomotor.........................................45
16. TABLES
Table 1: Advantages and Disadvantages of the single seat ..............................................15
Table 2: Advantages and Disadvantages of the double seat .............................................18
Table 3: Advantages and Disadvantages of the cage valve ..............................................20
Table 4: Advantages and Disadvantages of the diaphragm valve .....................................24
Table 5: Advantages and Disadvantages of the guillotine valve ........................................24
Table 6: Advantages and Disadvantages of the butterfly valve .........................................27
Table 7: Advantages and Disadvantages of the ball valve ................................................29
Table 8: Advantages and Disadvantages of the eccentric shutter valve............................32
Table 9: Combinations of valve fail-safe and positioning device positions.........................56
Table 10: Conversion of units ..........................................................................................114
Table 11: Critical pressure and critical temperature of a few selected materials .............116
Table 12: Mass volume and molar masse of a few selected materials ............................118
Item 5
; Item 6
2
Item 7 1
Item 1 5
6
Item 4
7
8
; Item 8 9
; Item 9
10
Item 3
Item 2
Rotary
; Linear
Gravitation
Pressure differential
; Cavitation
A positioning device
; Un electrovalve
An I/P converter
7 bars
3 PSI
To convert an electrical signal (4-20 mA) into a pneumatic signal (0.2 - 1 bar)
; Both
A linear valve
A piston valve
; A rotary valve
Tends to close it
; Tends to open it
Is direct
Both
Fail Open
; Fail Closed