Control valve

A control valve is a valve used to control fluid flow by varying the size of the flow passage as directed by
a signal from a controller.[1] This enables the direct control of flow rate and the consequential control of
process quantities such as pressure, temperature, and liquid level.

In automatic control terminology, a control valve is termed a "final control element".

Contents
Operation
Control action
Valve positioners
Types of control valve
Based on the pressure drop profile
Based on the movement profile of the controlling element
Based on the functionality
Based on the actuating medium
List of common types of control valve
See also
References
External links

Operation
The opening or closing of automatic control valves is usually done
by electrical, hydraulic or pneumatic actuators. Normally with a
modulating valve, which can be set to any position between fully
open and fully closed, valve positioners are used to ensure the
valve attains the desired degree of opening.

Air-actuated valves are commonly used because of their simplicity,

as they only require a compressed air supply, whereas electrically-
operated valves require additional cabling and switch gear, and
hydraulically-actuated valves required high pressure supply and
return lines for the hydraulic fluid.
The pneumatic control signals are traditionally based on a pressure
range of 3–15 psi (0.2–1.0 bar), or more commonly now, an
electrical signal of 4-20mA for industry, or 0–10 V for HVAC
systems. Electrical control now often includes a "Smart"
Air-actuated control valves each with
a 4–20 mA "I to P" converter integral
to a valve positioner. In this example
each positioner is comparing the
valve stem travel against control
signal, and applying any correction.
communication signal superimposed on the 4–20 mA control current, such that the health and verification
of the valve position can be signalled back to the controller. The HART, Fieldbus Foundation, and Profibus
are the most common protocols.

An automatic control valve consists of three main parts in which each part exist in several types and
designs:

Valve actuator – which moves the valve's modulating element, such as ball or butterfly.
Valve positioner – which ensures the valve has reached the desired degree of opening. This
overcomes the problems of friction and wear.
Valve body – in which the modulating element, a plug, globe, ball or butterfly, is contained.

Control action
Taking the example of an air-operated valve, there are two control
actions possible:

"Air or current to open" – The flow restriction decreases

with increased control signal value.
"Air or current to close" – The flow restriction increases
with increased control signal value.

There can also be failure to safety modes:

Showing the evolution of analogue
Air or control signal failure to close" – On failure of control loop signalling from the
compressed air to the actuator, the valve closes under pneumatic era to the electronic era.
spring pressure or by backup power.
Air or control signal failure to open" – On failure of
compressed air to actuator, the valve opens under
spring pressure or by backup power.

The modes of failure operation are requirements of the failure to

safety process control specification of the plant. In the case of
cooling water it may be to fail open, and the case of delivering a
chemical it may be to fail closed.

Valve positioners Example of current loops used for

sensing and control transmission.
The fundamental function of a positioner is to deliver pressurized Specific example of a smart valve
air to the valve actuator, such that the position of the valve stem or positioner used.
shaft corresponds to the set point from the control system.
Positioners are typically used when a valve requires throttling
action. A positioner requires position feedback from the valve stem or shaft and delivers pneumatic pressure
to the actuator to open and close the valve. The positioner must be mounted on or near the control valve
assembly. There are three main categories of positioners, depending on the type of control signal, the
diagnostic capability, and the communication protocol: pneumatic analog and digital.[2]

Processing units may use pneumatic pressure signaling as the control set point to the control valves.
Pressure is typically modulated between 20.7 to 103 kPa (3 to 15 psig) to move the valve from 0 to 100%
position. In a common pneumatic positioner the position of the valve stem or shaft is compared with the
position of a bellows that receives the pneumatic control signal. When the input signal increases, the
bellows expands and moves a beam. The beam pivots about an
input axis, which moves a flapper closer to the nozzle. The nozzle
pressure increases, which increases the output pressure to the
actuator through a pneumatic amplifier relay. The increased output
pressure to the actuator causes the valve stem to move. Stem
movement is fed back to the beam by means of a cam. As the cam
rotates, the beam pivots about the feedback axis to move the
flapper slightly away from the nozzle. The nozzle pressure
decreases and reduces the output pressure to the actuator. Stem
movement continues, backing the flapper away from the nozzle
until equilibrium is reached. When the input signal decreases, the
bellows contracts (aided by an internal range spring) and the beam
pivots about the input axis to move the flapper away from the
nozzle. Nozzle decreases and the relay permits the release of
diaphragm casing pressure to the atmosphere, which allows the
actuator stem to move upward. Through the cam, stem movement
is fed back to the beam to reposition the flapper closer to the Globe control valve with pneumatic
nozzle. When equilibrium conditions are obtained, stem movement diaphragm actuator and "smart"
stops and the flapper is positioned to prevent any further decrease positioner which will also feed back
in actuator pressure.[2] to the controller the actual valve
position
The second type of positioner is an analog I/P positioner. Most
modern processing units use a 4 to 20 mA DC signal to modulate
the control valves. This introduces electronics into the positioner design and requires that the positioner
convert the electronic current signal into a pneumatic pressure signal (current-to-pneumatic or I/P). In a
typical analog I/P positioner, the converter receives a DC input signal and provides a proportional
pneumatic output signal through a nozzle/flapper arrangement. The pneumatic output signal provides the
input signal to the pneumatic positioner. Otherwise, the design is the same as the pneumatic positioner[2]

While pneumatic positioners and analog I/P positioners provide basic valve position control, digital valve
controllers add another dimension to positioner capabilities. This type of positioner is a microprocessor-
based instrument. The microprocessor enables diagnostics and two-way communication to simplify setup
and troubleshooting.

In a typical digital valve controller, the control signal is read by the microprocessor, processed by a digital
algorithm, and converted into a drive current signal to the I/P converter. The microprocessor performs the
position control algorithm rather than a mechanical beam, cam, and flapper assembly. As the control signal
increases, the drive signal to the I/P converter increases, increasing the output pressure from the I/P
converter. This pressure is routed to a pneumatic amplifier relay and provides two output pressures to the
actuator. With increasing control signal, one output pressure always increases and the other output pressure
decreases

Double-acting actuators use both outputs, whereas single-acting actuators use only one output. The
changing output pressure causes the actuator stem or shaft to move. Valve position is fed back to the
microprocessor. The stem continues to move until the correct position is attained. At this point, the
microprocessor stabilizes the drive signal to the I/P converter until equilibrium is obtained.

In addition to the function of controlling the position of the valve, a digital valve controller has two
additional capabilities: diagnostics and two-way digital communication.[2]

Widely used communication protocols include HART, FOUNDATION fieldbus, and PROFIBUS.

Advantages of placing a smart positioner on a control valve:

1. Automatic calibration and configuration of positioner.

2. Real time diagnostics.

3. Reduced cost of loop commissioning, including installation and calibration.

4. Use of diagnostics to maintain loop performance levels.

5. Improved process control accuracy that reduces process variability.

Types of control valve

Control valves are classified by attributes and features.

Based on the pressure drop profile

High recovery valve: These valves typically regain most of static pressure drop from the inlet
to vena contracta at the outlet. They are characterised by a lower recovery coefficient.
Examples: butterfly valve, ball valve, plug valve, gate valve
Low recovery valve: These valves typically regain little of the static pressure drop from the
inlet to vena contracta at the outlet. They are characterised by a higher recovery coefficient.
Examples: globe valve, angle valve

Based on the movement profile of the controlling element

Sliding stem: The valve stem / plug moves in a linear, or straight line motion. Examples:
Globe valve,[3] angle valve, wedge type gate valve
Rotary valve: The valve disc rotates. Examples: Butterfly valve, ball valve

Based on the functionality

Control valve: Controls flow parameters proportional to an input signal received from the
central control system. Examples: Globe valve, angle valve, ball valve
Shut-off / On-off valve: These valves are either completely open or closed. Examples: Gate
valve, ball valve, globe valve, angle valve, pinch valve, diaphragm valve
Check valve: Allows flow only in a single direction
Steam conditioning valve: Regulates the pressure and temperature of inlet media to required
parameters at outlet. Examples: Turbine bypass valve, process steam letdown station
Spring-loaded safety valve: Closed by the force of a spring, which retracts to open when the
inlet pressure is equal to the spring force

Based on the actuating medium

Manual valve: Actuated by hand wheel
Pneumatic valve: Actuated using a compressible medium like air, hydrocarbon, or nitrogen,
with a spring diaphragm, piston cylinder or piston-spring type actuator
Hydraulic valve: Actuated by a non-compressible medium such as water or oil
Electric valve: Actuated by an electric motor
A wide variety of valve types and control operation exist. However, there are two main forms of action, the
sliding stem and the rotary.

The most common and versatile types of control valves are sliding-stem globe, V-notch ball, butterfly and
angle types. Their popularity derives from rugged construction and the many options available that make
them suitable for a variety of process applications.[4] Control valve bodies may be categorized as below:[2]

List of common types of control valve

Sliding stem
Globe valve – Flow control device
Angle body valve
Angle seat piston valve
Axial Flow valve
Rotary
Butterfly valve – Flow control device
Ball valve – Flow control device
Other
Pinch valve
Diaphragm valve – Flow control device

See also
Check valve – Flow control device
Control engineering – Engineering discipline that applies automatic control theory to design
systems with desired behaviors
Control system – System that manages the behavior of other systems
Distributed control system – Computerized control systems with distributed decision-making
Fieldbus Foundation
Flow control valve – Valve that regulates the flow or pressure of a fluid
Highway Addressable Remote Transducer Protocol, also known as HART Protocol
Instrumentation – Measuring instruments which monitor and control a process
PID controller – control loop feedback mechanism
Process control
Profibus
SCADA, also known as Supervisory control and data acquisition system – Control system
architecture for supervision of machines and processes

References
1. Instrument Society of America Standard S561.1, 1976. as reproduced in the "Fisher control
valve handbook" fourth edition 1977.
2. Emerson Automation Solutions (2017). "Control Valve Handbook" (https://www.emerson.co
m/documents/automation/control-valve-handbook-en-3661206.pdf) (PDF) (5th ed.). Fischer
Controls International LLC. Retrieved 2019-05-04.
 3. "What is Globe Valve? Working Principle & Function | Linquip" (https://www.linquip.com/ind
ustrial-directories/347/glob-valve). www.linquip.com. Retrieved 2021-11-25.
4. Hagen, S. (2003) "Control valve technology" Plant Services (http://www.plantservices.com/a
rticles/2003/124.html)

External links
Process Instrumentation (Lecture 8): Control valves (http://www.unisanet.unisa.edu.au/Infor
mation/100048info/IL8.doc) Article from a University of South Australia website.
Control Valve Sizing Calculator (http://www.enggcyclopedia.com/welcome-to-enggcyclopedi
a/calculators/control-valve-sizing) Control Valve Sizing Calculator to determine Cv for a
valve.
Goodwin Flow Control (https://www.goodwinflowcontrol.com/) Goodwin Axial Control Valves
website.

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