Valves Section 7

Item No. Description Item No. Description

1 Body 10 Stem
2 Bonnet 11 Spring Retainer
3 Main Disc 12 Stem Pin
4 Pilot Disc 13 Plunger
5 Disc Inserts 14 Fixed Core
6 Piston Ring 15 Coil Base
7 Disc Pin 16 Coil
8 Sleeve 17 Coil Cover
9 Spring 18 Lock Nut

FIGURE 7-20 - SOLENOID MOTOR ACTUATED VALVE

Control Valves

Control valves are a functional rather than a design classification. Control valves have design
features that have been developed and refined specifically for improvement of control valve
performance. As shown in Figure 7-21, control valves have an actuator that is powered by
energy from an independent source. The actuator moves the valve closure member in response
to an external signal. The movement is proportionate to the signal. Valve closure member
position changes in relation to the valve port or ports are thus controlled by and in proportion to
the external signal. Fluid flow through the valve is controlled by the valve closure member, so
that position changes will throttle, stop, start, or alter the routing of the flow. Control valves can
therefore be used to regulate a variety of process conditions, including flow rate, pressure,
temperature, liquid level, and input or output routing.

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Section 7 Valves

Variations in control valve

configurations are practically endless,
but the most common arrangements
have a globe type valve with specially
designed trim and a pneumatically
operated diaphragm actuator. Ball,
butterfly, diaphragm, rotary plug, and
sliding gate valves are also used as
control valves. Actuators can also be
pneumatic pistons (cylinders),
hydraulic cylinders, electric solenoids,
and various combinations of these.

It is particularly important to maintain

access and removal space for control
valves when selecting an installation
FIGURE 7-21 - CONTROL VALVE location.

Control Valve Actuators

Pneumatically operated control valve actuators are the most popular type in use, but electro-
hydraulic actuators are also widely used. The spring and diaphragm pneumatic actuator is most
commonly specified, due to its dependability and its simplicity of design. Pneumatically operated
piston actuators provide integral positioner capability and high stem force output for demanding
service conditions. Adaptations of both spring and diaphragm and pneumatic piston actuators
are also available for installation on rotary shaft control valves.
Electro-hydraulic actuators are more complex and more expensive than pneumatic actuators.
They offer advantages where no air supply source is available, where low ambient temperatures
could freeze condensed water in pneumatic supply lines, or where usually large stem forces are
needed. The following is a summary of the design and operating characteristics of some popular
actuator styles:

Diaphragm Actuators

These are widely available in a great range of sizes. The two basic types of diaphragm actuators
are shown in Figure 7-22. One type is generally called a direct acting diaphragm actuator, and
the other a reverse acting diaphragm actuator.

The direct acting type has a spring that holds the valve in the open position when the air chamber
above the diaphragm is not pressurized. Air pressure counteracts the spring force, and fluid
pressure against the valve closure member, to push the valve stem downward. The air pressure
is controlled by a positioner, so that the pressure is increased when the valve closure member
must be moved closer to the set (for closer throttling), and further increased if the valve is to be
completely closed. The reverse acting type works in the opposite manner. The spring force holds
the valve in the closed position and air pressure moves it to a partially open (throttled) or fully
open position. The chamber above the diaphragm in a reverse acting diaphragm actuator must
be vented.

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 Valves Section 7

Diaphragm actuators are simple, reliable, and available in a multitude of sizes, which is why they
are used on most control valves. However, the diaphragm will not withstand high pressure.
Thus, a very large actuator is needed to operate a valve having high unbalanced or generated
force.

Item No Description Item No Description

15 Packing Box Gasket 39 Diaphragm
17 Yoke 40 Diaphragm Plate
18 Cap Screw 41 Diaphragm Washer
19 Gasket 43 Upper Diaphragm Case
20 Packing Nut 44 Lower Diaphragm Case
21 Snap Ring 45 Diaphragm Case Cap Screw
22/22A Actuator Spring 46 Diaphragm Case Nut
26 Actuator Stem 56 Travel Indicator Scale
30 Packing Box 57 Machine Screw
31 Nut (Actuator Stem) 70 Ball & Retainer
32 Yoke Packing 71 Spring Barrel
33 Spring Guide 72 Spring Barrel Cap
34 Spring Button 73 Ball Bearing Race
35 Pipe Plug 74 Cap Screw
36 Spring Adjuster 76 Spacer Ring
37 Bushing

FIGURE 7-22 - DIAPHRAGM ACTUATORS

1996:Rev.2 Piping/Mechanical Handbook 7-23

Section 7 Valves

Piston Actuators

Unlike diaphragm actuators,

hydraulic and pneumatic cylinders
are made to withstand high
pressures. Therefore, these are
often more suitable for a valve
that requires high operating force.
The cylinder contains a single
acting or double acting piston. As
shown in Figure 7-23, the single
acting piston is spring loaded and
functions in much the same
manner as a diaphragm actuator.
The double acting piston is moved
back and forth by pressurizing or
increasing the pressure on one
side while concurrently exhausting
or decreasing the pressure on the
other side. Double acting
pneumatic pistons with positioners
are more commonly used than the
other piston types for control
valve actuators.

Electro-Hydraulic Actuators

These actuators require only

Item No. Description Item No. Description electrical power to the motor and
1 Yoke 19 Connector
2 Stem Lock 20 Regulator-Positioner an electrical input signal from a
Assembly controller. They are ideal for
3 Stem Lock Bolt 21 Elbow
4 Stem Lock Nut 22 Actuating Tubing
isolated locations where
Assembly pneumatic supply pressure is not
5 Piston Rod 23 Rate Spring available but where precise
6 Piston Rod O-Ring 24 Dome
7 Adapter Screw O-Ring 25 Spring Button Assembly control of valve plug position is
8 Base Plate 26 Seal Tube Retainer needed. The units are usually
9 Base Plate O-Ring 27 Seal Tube Gasket self contained, including motor,
10 Nut (Actuator Stem) 28 Spring
11 Piston Rod Washer 29 Dome Retaining Ring pump, and double acting
12 Piston Rod O-Ring 30 Adapter Screw hydraulically operated piston
13 Travel Stop 31 Adapter Nut
14 Seal Tube 32 Stem Boot
within a weather proof or
15 Seal Tube O-Ring 33 Travel Plate explosion proof casing.
16 Caution Plate 34 Travel Plate Screw
17 Drive Screw 35 Travel Plate Nut
18 Loading Tubing 36 Name Plate
Assembly

FIGURE 7-23 - PISTON ACTUATOR

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 Valves Section 7

Valve Positioners

Many valve positioners have been developed and are presently available. In function, they are
alike, although there are various shapes, styles, and operating principles. Positioners are
generally mounted on the side of diaphragm actuators and on the top of piston actuators. They
are connected mechanically to the valve stem or piston so that stem position can be compared
with the position dictated by the controller.

An auxiliary positioner is used for systems where it is necessary to:

• Split range the controller output to more than one valve
• Amplify the controller output signal pressure above the standard range to provide increased
actuator thrust or stiffness
• Provide the best possible control with minimum overshoot and fastest possible recovery
following a disturbance or load change where long controller instrument lines are involved

Pneumatic Positioners

The positioner schematic shown in Figure 7-24 shows a pneumatic positioner connected for
double acting service on a piston actuator. Tension on the range spring provides feedback to the
positioner, which will vary as the stem position changes. The spring loading force is applied
through the lever and cam to the positioner's input capsule. Control instrument pressure is
applied between the diaphragms in the input capsule. Therefore, the input capsule serves as a
force balance member, matching the valve stem position (as measured by tension on the range
spring) to the control instrument signal.
When the opposing forces balance exactly, the system will be in equilibrium and the stem will be
in the exact position called for by the control instrument. If the opposing forces are not in
balance, the input capsule will move up or down, and by means of the pilot valves, will change the
output pressures. This will move the stem until the tension on the range spring opposes exactly
the control instrument pressure.

FIGURE 7-24 - PNEUMATIC POSITIONERS - SCHEMATIC

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Section 7 Valves

Electro-Pneumatic Transducers

Shown in Figures 7-25 and 7-26, the transducer receives a direct current input signal and uses a
torque motor, nozzle flapper, and pneumatic relay to convert the electric signal to a proportional
pneumatic output signal. Nozzle pressure operates the relay and is piped to the torque motor
feedback bellows to provide a comparison between input signal and nozzle pressure. The
transducer can be mounted directly on a control valve and operate the valve without need for
additional boosters or relays. On-off electro-pneumatic transducers are also available and are
commonly used to replace solenoid valves in intrinsically safe systems.

FIGURE 7-25 - ELECTRO-PNEUMATIC POSITIONER - SCHEMATIC

Control Valve Bodies and Trim

Basic body styles are essentially the same as those used for manually operated valves. Globe,
angle, and Y-pattern bodies are used and these have a reciprocating valve closure member that
functions in the same manner as the disc in a comparable manually operated valve. However, in
a control valve, the closure member is called a plug or valve plug instead of a disc. Again, this is
a reciprocating plug and not the rotary plug that constitutes the closure member in a plug valve.
Rotary plugs are also used in some control valves. Ball valves, butterfly valves, and diaphragm
valves are sometimes used as control valves. The globe style body, however, is the most
commonly used type. Plugs and seats in globe style control valves are much more specialized
than comparable parts of manually operated globe valves. Several different plug shapes are
used, and each shape is designed for a specific combination of fluid characteristics and operating
conditions.

1996:Rev.2 Piping/Mechanical Handbook 7-26