19-May-21

An exclusive training session for Pendekar

Monday, April 19, 2021

Agenda

1 Safety Moment

2 Fundamentals

3 Control Valve Sizing

4 Cavitation and Flashing

5 Fisher Technology for Cavitation and Flashing

6 Control Valve Noise

7 Pneumatic Accessories used in Control Valves

8 Positioners

9 Q&A

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Safety Moment

Safety Moment
Check your posture regularly.
• Maintain proper posture, paying careful attention to positioning of head, neck, spine, arms, wrists, hips, thighs and
feet.
Don’t ignore discomfort!
• Discomfort is an annoyance and can inhibit productivity. At worst, it can lead to injuries and/or disabilities. It’s
important to address discomfort and the possible causes of it as soon as possible.
Take your breaks in full
• Take frequent mini-breaks throughout the day to give muscles and joints a chance to rest and recover. Your body
wants you to move! You can use a simple clock or timer on the screen when you take a break. If you return to
your desk after only 40 minutes, walk for another 20.
Avoid distractions
• If possible, work in a quiet room with the door closed. If there are distracting noises, try headphones, ear plugs,
soft music or a quiet fan to reduce or mask the sounds.
Avoid glare
• Reduce or eliminate glare by using window shades, diffusers on overhead lighting and anti-glare filters for
computers.
Continue to socialize.
• Don’t forget that not all stress is physical. To help fill the socializing gap while working remotely, buddy up with a
friend who works elsewhere and is going through the same experience. Hopping on a social video call instead
isn’t a bad idea, either.
Exercise
• We all know that exercise is essential for overall health. Make sure that you make time to exercise when working
at home.

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Fundamentals

Sizing Considerations

• Inlet pressure • Size

• Outlet pressure • Accessories

• Flow rate • Flow characteristic

• Temperature • Positioner usage

• Vapor pressure/Critical Pressure • Stroking speed requirement

• Viscosity • Cavitation/Flashing

• Specific Gravity / Density/ MW • Noise

• Inlet and outlet pipe size and schedule

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Control Loop

Setpoint (SP)

Controller
Output Controller

PV

Transmitter

Sensor

loop1

Pressure/Temperature Ratings

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Service Life

• Material ratings

• Chemical compatibility

• Erosion

• Cavitation

• Flashing

• Noise

Pressure Drop Considerations

10

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Flow capacity

• Flow capacity of the valve is generally specified as Cv in ISA term

• Definition of Cv:

– “The number of US gallons of water per minute at 60 deg F that will pass through with

1 psi pressure drop across the valve”

• Sliding stem valve capacities are published at different percentage of opening

• Rotary valves capacities are published for different degree of rotation

11

Flow capacity & Factors that drives Cv

12

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Flow Characteristics

• The relationship between the flow coefficient and valve travel as the valve
travels from 0 to 100 percent open

13

Flow Characteristics

• Common flow characteristics are

– Quick opening

• Higher gain at lower valve travel

• Preferred for on/off service

– Linear

• Constant gain through out valve travel

• Preferred for constant pressure drop

– Equal percentage

• Lower gain at lower travel and higher gain at higher travel

• Good for varying pressure drop

14

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Globe Valve Components

https://www.youtube.com/watch?v=8hfvHXhLvGY&fe
ature=youtu.be
15

Shutoff/Leakage class

ANSI/FCI/IEC Leakage Classes

16

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Shutoff/Leakage class

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Control Valve Sizing

Compressible and Incompressible Fluids

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Basic Flow Equation

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Choked Flow

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Vaporization when PVC < PV – Choked Flow

21

Swage Effects

22

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Gas / Vapor Sizing

23

Gas / Vapor Sizing

24

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Gas / Vapor Sizing

25

Gas / Vapor Sizing

26

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Cavitation and Flashing

https://www.youtube.com/watch?v=gRsvO4Gpnf0

Cavitation: Bubble Formation & Collapse

28

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Cavitation Damage

Cavitation Damage That Results from Imploding Bubbles

29

Fisher Technology for

Cavitation and Flashing

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Pressure Drop Staging

31

Material Hardness

Material Hardness

17-4 PH H900 40 Rc

440C 59 Rc

316/Colmonoy 6 58 Rc

316/Alloy 6 42 Rc

420 SST HT 52 Rc

416 SST HT 38 Rc

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Control Valves for Cavitating Applications

- Cavitation Damage
- Typical Damaged Plug

Methods of Handling Cavitation

• Isolation
• Elimination

33

Isolation

Cavitrol III-I Stage

34

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Isolation

Angle Valve with Liner

35

Cavitrol III 2 Stage Trim

36

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Cavitrol III 3 Stage Trim

37

Control Valve Noise

https://www.youtube.com/watch?v=6gZqvykrxJ0

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Typical Spectrum Control Valve Noise

120

110

100

90

80

70

60
0 100 160 250 400 630Hz 1 1.6 2.5 4 6.3 10 15KHz

39

dBA Correction

5
0
-5
-10
-15
-20
dB -25
-30
-35
-40
-45
-50
20 50 100 200 500 1000 2000 5,000 10,000

Frequency in Hertz

40

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dBA Levels

Sound dBA

Vacant Room 40

Office 65

Busy Street 85

Jet Engine 125

140 dbA is the threshold of pain.

41

OSHA Exposure Limits

120

110

Allowable Level 100

of Pressure
90
(dBA)
80

70

60
0 1 2 3 4 5 6 7 8

Permissible Exposure
(Hours in a Day)

42

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Pipe Wall Effect on Noise Level

• DLpAK Correction for Steel Pipe Wall Attenuation, dBA
Page Steel Schedule
Size,
Inch 10 20 30 40 60 80 100 120 140 160 STD XS XXS
1 --- --- --- –19.01 --- –21.6 --- --- --- –24.5 –19.0 –21.6 –27.6
1-1/2 --- --- --- –19.81 --- –22.6 --- --- --- –25.6 –19.8 –22.6 –28.6
2 --- --- --- –20.41 --- –23.4 --- --- --- –27.3 –20.4 –23.4 –29.4
3 --- --- --- –23.41 --- –26.2 --- --- --- –29.5 –23.4 –26.2 –32.3
4 --- --- --- –24.21 --- –27.2 --- –29.5 --- –31.2 –24.2 –27.2 –33.2
6 --- --- --- –25.8 1
--- –29.5 --- –31.8 --- –33.9 –25.8 –29.5 –35.5
8 --- –24.9 –25.8 –27.11 –29.1 –30.9 –32.4 –34.1 –35.1 –36.1 –27.1 –30.9 –35.8
10 --- –24.9 –26.7 –28.21 –31.0 –32.4 –34.1 –35.5 –37.0 –38.0 –28.2 –31.0 ---
12 --- –25.1 –27.5 –29.3 –32.1 –33.8 –35.6 –37.1 –38.1 –39.5 –28.6 –31.1 ---
14 –25.4 –27.1 –28.71 –30.0 –32.6 –36.6 –36.6 –38.0 –39.1 –40.1 –28.7 –31.2 ---
16 –25.3 –27.2 –28.8 1
–31.3 –33.6 –37.6 –37.6 –39.0 –40.4 –41.3 –28.8 –31.3 ---
18 –25.3 –27.2 –30.1 –32.3 –34.8 –38.6 –38.6 –40.1 –41.2 –42.3 –28.8 –31.3 ---
20 –25.4 –28.91 –31.4 –32.9 –35.6 –39.1 –39.1 –40.9 –42.3 –43.3 –28.9 –31.4 ---
24 –25.6 –29.91 –32.6 –34.4 –37.4 –41.3 –41.3 –42.8 –43.9 –45.0 –29.1 –31.6 ---
30 –27.7 –31.8 –33.7 --- --- --- --- --- --- --- –29.3 –31.8 ---
36 –28.0 –32.1 –34.1 –35.6 --- --- --- --- --- --- –29.6 –32.1 ---
42 --- --- --- --- --- --- --- --- --- --- –29.8 –32.3 ---
44 --- --- --- --- --- --- --- --- --- --- –29.9 –32.4 ---
48 --- --- --- --- --- --- --- --- --- --- –30.0 –32.5 ---
52 --- --- --- --- --- --- --- --- --- --- –30.2 –32.7 ---
56 --- --- --- --- --- --- --- --- --- --- –30.3 –32.8 ---
60 --- --- --- --- --- --- --- --- --- --- –30.4 –32.9 ---
1. Standard schedule.

Correction to Base as a Function of Pipe Size

43

Whisper III Level D Cage

44

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Source Treatment Methods

Globe Valve and Inline Diffuser

45

Noise Control Trim Performance

• Whisper I Slotted Cage

– Reduction of 12-18 dBA

• Whisper III Drilled Hole Cage

– Reduction of 15-30 dBA

• Whisper Trim with Diffuser

– Reduction of 30-40 dBA

46

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Path Treatment

Sound Pressure
Levels Outside Heavy Acoustical
of 6 Inch Pipe Walled Pipe Insulation
Untreated (SCH 80) (2’’ Thick) Untreated Untreated
Pipe (SCH 40) Pipe (SCH 40) Pipe (SCH 40)
106.3 dBa 96 dBa Inline Silencer
110 dBa 110 dBa 85 dBa
85 dBa

47

Pneumatic Accessories
used in Control Valves

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Filters

Filter

• Removes dust, dirt, pipeline scale & other impurities from Air Supply

Factors affecting selection of Filters

• Filter rating

• Cv Requirement

49

Typical Filter

Inlet Outlet

50

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Check Valve

Closed Check ValveOpen Check Valve Flow in only 1 direction

Down to Up

51

Quick Release Exhaust Valves

• Reduces the time to exhaust the Actuator

• Casing pressure exhausted to atmosphere based on differential pressure

• Exhaust port Cv is much higher which results in Faster Stroking

52

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Quick Release Valve

53

Quick Release Valve Operation

54

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Solenoid Valves

• A solenoid valve is an electromechanical valve for use with liquid or gas

controlled by running or stopping an electrical current through a solenoid,

which is a coil of wire, thus changing the state of the valve.

• A solenoid valve has two main parts:

– the solenoid

– the valve

55

Solenoid Valves

• The solenoid converts electrical energy into mechanical energy which, in turn,

opens or closes the valve mechanically.

• A spring may be used to hold the valve opened or closed while the valve is not

activated.

• Very fast response as it is electrical based operation

56

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Fig.: Solenoid Valve

57

Initiating The Inherent Fail Mode

58

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Volume Booster

• Principle of Operation:

– Boosters accept a pneumatic input which is typically the control signal from

pneumatic controller or I/P transducer & Regulator Supply pressure from the

plant air system.

– The input pressure modulates the supply pressure to produce an output

pressure that is proportional to the input pressure.

59

Volume Booster

• I/O pressure & O/P pressure registers on upper and lower diaphragm assembly.

• Any change in the position of the diaphragm assembly will cause a change in

the position of the supply valve and the exhaust valve.

60

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Fig.: Volume Booster

Input Pressure

Supply Pressure Exhaust

Output Pressure

61

Positioners
https://www.youtube.com/watch?v=dNq4H9WfrfE

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Role of Positioner

63

Role of Positioner

Role of Positioner
• A device that keeps the valve stem at desired
Position with greater accuracy and stability
• Provides feedback to the control system
• Reduces dead band and hysteresis in the system
• Friction: Leading cause of imprecise valve stem
positioning (Friction from packing, seals and
bearings can cause the valve stem or shaft to
stick in a fixed position even though the actuator
loading pressure is changing)

64

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Digital Valve Controllers (SMART Positioners)

• They are high performance I/P positioners

• Networking Features (HART, Fieldbus)
• Auto Calibration
• Accuracy of Stem positioning
• Gain adjustment
• Change of characteristics without cams
• Alarms
• Travel Limits
• Integral position transmitter
• Contactless feedback
• Diagnostics

https://www.youtube.com/watch?v=Uc0W-j_g2EI
65

DVC 2000

• Small

• Intrinsically Safe

• Single acting

• Linkage-less, non-contact, position feedback

• Local User Interface (LCD and pushbuttons)

• Auto tuner (tuning based on actuator size)

• Diagnostic tiers (AC, HC, AD, PD)

• NAMUR mounting

• Complimentary to the DVC6200 Series

• Limit Switches (soft)

• 4-20mA Position Transmitter

66

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DVC6200 Series Family

HART Fieldbus Profibus

DVC 6200 additional features

- Double Acting
- Can be Intrinsic safe or Explosion Proof

SIS
67

DVC 6200 Communication Protocols

• HART

• Fieldbus

• Profibus

68

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Key Features

– Compatible with Existing 4-20 mA systems

– Protects investment in current systems

– Wide breadth of products on the market

– Non-Proprietary -- Open and available for all

HART
– Uses exiting cables, good for replacement market
FIELD COMMUNICATIONS PROTOCOL

– Reduced maintenance costs from diagnostics

– Better rangeability and accuracy

– Fewer valve accessories (e.g., combined functionality

of I/P, positioner, stem position feedback transmitter,
limit switch, etc.)
69

DVC Features HART

HART (Highway Addressable Remote Transducer)

- Two wire 4-20 ma signal

Frequency Shift Keying

70

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Foundation Fieldbus

• All digital, two-way, multi-drop communication link among intelligent field

devices and automation systems

• Essentially a Local Area Network (LAN) for field devices

• Fully digital, no 4 - 20mA

• Technology is owned and administered by the Fieldbus Foundation

• Significant hardware and installation savings like cabling, limit switches,

position transmitters etc. 71

FoundationTM Fieldbus - How it Connects

Control On/Off Motor Temp

Tx’s
Valves Actuators Starters Tx
72

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DVC 6200 Tiering

HART FIELDBUS

AC Auto Calibration FD Fieldbus Diagnostics

HC HART Communicating AD Advanced Diagnostics

AD Advanced Diagnostics PD Performance Diagnostics

PD Performance Diagnostics -

73

Some Advanced Diagnostics

25

• Visibility to Physical Valve Problems 20

Actuator Pressure (psi)

– Worn Seat/Seals/Packing 15

– Tuning Problems
Open

10

– Hysteresis/Dead band issues 5

AS FOUND WITH UPSTREAM CHECK VALVE

– High/Low levels of friction 0
PARTS STUCK BETWEEN BALL & SEAL X: -22.21
Y: 10.27
-5
50 40 30 20 10 0 -10 -20
Travel (deg)

74

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