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Control Valve Hand Book

&
Terminology

DEMBLA VALVES LIMITED.


1, ADARSH INDUSTRIAL ESTATE,
POKHARAN ROAD, No. 1, UPVAN,
THANE 400 606.
MAHARASHTRA, INDIA.
Phone : 022 25853899 / 25888234,
Fax : 25853429
E-Mail : info@dembla.com , mkt@dembla.com
Web Site : www.dembla.com

Dembla
DEMBLA VALVES LIMITED.

Control Valves Do What They Are Told!


Being the Final Control Element in a system is not an easy job. To start with, you are
blamed for any and all problems that crop up in the process. You are subjected to
corrosion, high velocity, cavitation, flashing liquids, cryogenic temperatures, high
temperatures, abrasion, and thermal shock. You are expected not only to throttle along
through all this, but most likely, you are also being asked to act as a block valve and shut
off tight.
As you work with control valves always keep in mind that A CONTROL VALVE

ONLY DOES WHAT IT IS TOLD TO DO.

A Control Valve is a power-operated device used to modify the fluid flow rate in a
process system. Well, what happens if the power is cut off? When a Control Valve is
sized or selected to do a particular job, one of the first questions you should consider is
how that valve will respond in the event of a loss of signal or power. This is called its
"fail-safe mode" and knowing the fail-safe mode is the key to troubleshooting it.
In most applications (about 80%), it is desirable for valves to fail closed. In other
applications, you might want a valve to fail open or fail in place. Safety concerns and
process requirements will mandate the fall mode of the valve.
When a valve is not sitting in its fail position, is is being told how and when to
move by some external signal.
By the comments one hears, you would be led to believe that control valves sit around
and think up things to do on their own. Perhaps this will some day be true when all
control valves are "smart."
If a Control Valve is observed in an unstable condition or appears to not be
responding correctly to an input signal, remember that something is telling the valve to
behave that way.
A control valve is only as strong as its weakest link.
When the 1965 Ford Mustang first appeared, it was powered by a 6-cylinder engine
with a 3-speed transmission - but it had a 140 m.p.h.(225 k.p.h.) speedometer. The fact
that it had a 140 m.p.h.(225 k.p.h.) speedometer did not mean it could actually travel
that fast. In the same way, a control valve with a 600# rated valve body cannot throttle
and shut off against 1440 pounds of pressure.

II

Control Valve Features


There are two basic types of control valves: rotary and linear. Linear-motion control
valves commonly have globe, gate, diaphragm, or pinch - type closures. Rotary-motion
valves have ball, butterfly, or plug closures. Each type of valve has its special generic
features, which may, in a given application, be either an advantage or a disadvantage.

Linear Valve Features

TORTUOUS FLOW PATH


LOW RECOVERY
CAN THROTTLE SMALL FLOW RATES
OFFERS VARIETY OF SPECIAL TRIM
DESIGNS
SUITED TO HIGH-PRESSURE APPLICATIONS
USUALLY FLANGED OR THREADED
SEPARABLE BONNET

Rotary Valve Features

STREAMLINED FLOW PATH


HIGH RECOVERY
MORE CAPACITY
LESS PACKING WEAR
CAN HANDLE SLURRY AND ABRASIVES
FLANGELESS
INTEGRAL BONNET
HIGH RANGEABILITY

III

Control Valve Classification

In addition to linear and rotary, control valves are also classified according to their guiding systems
and the types of services they are used in.

IV

Actuators

Feature Comparison
Spring and Diaphragm
Advantages

Disadvantages

Lowest Cost

Limited Output Capability

Can Throttle Without a


Positioner

Large Size and Weight

Simplicity
Inherent Fail-Safe Action
Low Supply Pressure
Required
Adjustability
Easily Maintained
Pneumatic Piston
Advantages

Disadvantages

High Torque Capability

Fail-Safe Requires Accessories or


Addition of Spring

Compact

Positioner Required for Throttling

Lightweight

Higher Cost

Adaptable to High Ambient


Temperature

High Supply Pressure Required

Fast Stroking Speed


Relatively High Actuator
Stiffness
Electric Motor
Advantages

Disadvantages

Compactness

High Cost

Very High Stiffness

Lack of Fail-Safe Action

High Output Capability

Limited Duty Cycle


Slow Stroking Speed

Electrohydraulic
Advantages

Disadvantages

High Output Capability

High Cost

High Actuator Stiffness

Complexity and Maintenance


Difficulty

Excellent Throttling Ability

Large Size and Weight

Fast Stroking Speed

Fail-Safe Action Only With


Accessories

The key is to start with the fail-safe mode of the control valve.

Control Valve "Fail-Safe" Positions


Cause of Fail-Safe Condition: Loss of Air Pressure

Used with
sliding stem control valves: i.e. globe-style valves. Can be
accomplished two ways:
A. LINEAR SPRING/DIAPHRAGM ACTUATORS.

1. Fixed seat ring/plug orientation. Springs are interchanged


to either above or below actuator diaphragm.

2. Fixed spring orientation. Plug and seat ring positions are


reversed relative to each other. In the Fail Open design, plug
travel is above the valve seat. In the Fail Closed design, plug
travel is below the seat.

VI

Rotary Spring/Diaphragm Actuators


Used with rotary control valves; i.e. butterfly, eccentric plug.
Reversing the fail mode for this type of valve is normally
accomplished by reversing the location of lever arm and plug. In order
to maintain consistency, ATO-FC action will be considered as
"Reverse" action for rotary or sliding-stem control valves.

VII

Valve Positioners
A valve Positioner is a device used to increase or decrease the air pressure operating the
actuator until the valve stem reaches the position called for by the instrument controller.
Positioners are generally mounted on the side or top of the actuator. They are connected
mechanically to the valve stem so that stem position can be compared with the position
dictated by the controller.
A positioner is a type of air relay which is used between the controller output and the
valve diaphragm. The positioner acts to overcome hysteresis, packing box friction, and valve
plug unbalance due to pressure drop. It assures exact positioning of the valve stem in
accordance with the controller output.

Reasons To Use Positioners


Increase control system resolution: i.e. fine control.
Allow use of characteristic cams.
Minimize packing friction effects: i.e. high-temperature packing.
Negate flow-induced reactions to higher pressure drops.
Increase speed of response to a change in process.
Allow split ranging.
Overcome seating friction in rotary valves.
Allow distances between controller and control valve.
Allow wide range of flow variation: i.e. operate at less than 10% travel
under normal conditions.
Allow increased usage of 4-20 mA electronic signal.
Increase fast venting (unloading) capability.
Permit use of piston actuators.
Facilitate operation when the higher number in the bench-set range is
greater than 15 psig: i.e. 10-30 psig, 6-30 psig, etc.

VIII

How Positioners Work


Although there are many different types of positioners, the basic principles of operation
are similar for all of them.
Principle of Operation:
The positioner is mechanically connected to the stem of the valve. This stem position is
compared with the position called for by the instrument controller, i.e. by the instrument output
air signal. A separate air supply is brought into the positioner for positioning the valve at exactly
the point called for by the controller.

IX

Direct-Acting and Reverse-Acting Positioners


The terms "direct" and "reverse" are frequently used when discussing control valves, positioners, and
controllers. While the definitions of direct and reverse seem pretty straightforward, they cause quite a bit of
confusion - especially when split-ranging is done.
The key to working with control valves and controllers is to remember that there must always be a balance
maintained in the system. "Direct" and "reverse" are kind of like "positive" and "negative" in that where you
find one you will usually find the other.
While control valve bodies and control valve actuators can be described as being direct acting or reverse
acting, thinking about such things when working through a system problem only adds to the confusion.
Therefore, it is always best to consider the FAIL SAFE mode of the valve and simply let the control valve be
what it may be.
Positioners, 99% of the time, will usually mimic the input signal from the controller. That is, they will be
DIRECT ACTING.
Direct-Acting Positioner
Input Decreases
Output Decreases

Input Increases
Output Increases

Equals

Equals
Increasing Signal from
Controller

Increasing Output from


Positioner

Decreasing
Signal
From
Controller

Decreasing
Output From
Positioner

Another reason the direct-acting pneumatic positioner is so popular is that it can be by-passed and the control
valve will respond to the input signal from the controller as though the positioner were in the control loop. If a
positioner malfunction occurs or if the positioner causes the control valve to become unstable, it can be easily
by-passed. Many control valves in the field are operating with a by-passed positioner.
Reverse-acting positioners are sometimes used on control valves, but their appearance is rare. Occasionally one
will be found in a split-ranging sequence.
Reverse-Acting Positioner
Input Decreases
Output Increases

Input Increases
Output Decreases

Equals

Equals
Increasing Signal from
Controller

Decreasing Output from


Positioner

Decreasing
Signal
From
Controller

Increasing
Output From
Positioner

Direct-Acting and Reverse-Acting Controllers


Controllers can be set up in either direct or reverse modes. It was stated that 99% of the positioners are direct
acting, and it follows that if a balance is to be maintained in the control loop that 99% of the controllers will be
reverse acting. If the control valve and its controller are not in balance, the control valve will either go to the
wide-open position and stay there, or it will stay closed and act as though it is not responding. This situation can
normally be corrected by reversing the action of the controller.
Direct-Acting Controller
Setpoint Increases
Output Increases

Setpoint Decreases
Output Decreases

Equals

Equals

Increase
in
Setpoint

Decrease
in
Setpoint

Increase
in
Output

Decrease
in
Output

Reverse-Acting Controller
Setpoint Increases
Output Decreases

Setpoint Decreases
Output Increases

Equals
Increase
in
Setpoint

Equals
Decrease
in
Setpoint

Decrease
in
Output

Increase
in
Output

Two of the more common control valve uses are for pressure control. In both instances, the controllers are
reverse acting. Most pressure-reducing valves will be fail-closed and most back-pressure control valves will be
fail-open. If the pressure-reducing valve were fail-open or the back-pressure valve fail-closed, then the controllers
would have been direct acting.

XI

Control Valve Flow Characteristics


Trim design will affect how the valve capacity changes as the valve moves through its
complete travel. Because of the variation in trim design, many valves are not linear in nature.
THE RELATIONSHIP BETWEEN VALVE CAPACITY AND VALVE TRAVEL IS
KNOWN AS THE FLOW CHARACTERISTIC OF THE VALVE. Valve trims are
specially designed, or characterized, in order to meet the large variety of control application
needs. This is necessary because most control loops have some inherent nonlinearities, which
you can compensate for when selecting control valve trim.
Charts similar to Figure 1 (see below) are used to illustrate various control valve flow
characteristics. The percent of full flow through the valve is plotted against valve stem position.
The curves shown are typical of those available from valve manufacturers. These curves are
based on CONSTANT PRESSURE DROP across the valve and are called INHERENT FLOW
CHARACTERISTICS.
The quick-opening characteristic provides large changes in flow for very small changes in lift.
It usually has too high a valve gain for use in modulating control. So it is limited to on-off
service, such as sequential operation in either batch or semi-continuous processes.
The majority of control applications are valves with linear, equal-percentage, or modified-flow
characteristics.

Linear - flow capacity increases linearly with valve travel.


Equal percentage - flow capacity increases exponentially with valve trim travel; equal
increments of valve travel produce equal percentage changes in the existing Cv.
A modified parabolic characteristic is approximately midway between linear and
equal-percentage characteristics. It provides fine throttling at low flow capacity and
approximately linear characteristics at higher flow capacity.

When valves are installed with a pump, pipes, fittings, and other process equipment, the
pressure drop across the valve will vary as the plug moves through its travel. When the
actual flow in a system is plotted against valve opening, the curve is called the
INSTALLED FLOW CHARACTERISTIC.
Figure 1
Inherrent Flow Characteristics For Common Valve Trim Designs

XII

F1 - Pressure Recovery Factor


A valve design that dissipates a considerable amount of flow-stream energy due
to turbulence created by the contours of the flow path. Consequently, pressure downstream of the valve
vena contracta recovers to a lesser percentage of its inlet value than a valve with a more streamlined
flow path. The F1 factor does not vary with travel to any significant degree.
LOW-RECOVERY RATE:

A valve design that dissipates relatively little flow-stream energy due to


streamlined internal contours and minimal flow turbulence. Therefore, pressure down stream of the
valve vena contracta recovers to a high percentage of its inlet value. The F1 factor of a high recovery
valve will vary with its plug travel.
HIGH-RECOVERY RATE:

Pressure Recovery Factor (F1)


The graph below represents actual test data of a butterfly valve showing change in F 1 with plug rotation.
The data demonstrate why a rotary control valve can suddenly go into cavitation as the valve opens up.

XIII

F1 - (Flow Recovery Coefficient)


F1 = The valve pressure recovery factor, a dimension less quantity. (Measured when valve is not choked.)

he Vena Contracta is the place along the axis of flow, just beyond the orifice, where the jet steam contracts to its minimum cross-sectiona
area. Note: It is at this point that the velocity is at its highest, and the fluid pressure is at its lowest.

XIV

Pressure vs. Temperature for Selected Metals

XV

Seat Leakage Classifications

Rule of Thumb:
There is no such thing as "Bubble Tight."
Control valves are designed to throttle. However, this is not a perfect world, and control
valves are also usually expected to provide some type of shut-off capability. A control
valve's ability to shut off has to do with many factors. The type of valves for instance. A
double-seated control valve will usually have very poor shut-off capability. The guiding, seat
material, actuator thrust, pressure drop, and the type of fluid can all play a part in how well a
particular control valve shuts off.
There are actually six different seat leakage classifications as defined by ANSI/FCI 70-21976. But for the most part you will be concerned with just two of them: CLASS IV and
CLASS VI. CLASS IV is also known as METAL TO METAL. It is the kind of leakage rate
you can expect from a valve with a metal plug and metal seat. CLASS VI is known as a
SOFT SEAT classification. SOFT SEAT VALVES are those where either the plug or seat or
both are made from some kind of composition material such as Teflon.
Valve Leakage Classifications

Class I. Identical to Class II, III, and IV in construction and design intent, b
actual shop test is made.

Class II. Intended for double-port or balanced singe-port valves with a met
ring seal and metal-to-metal seats. Air or water at 45 to 60 psig is the test fl
Allowable leakage is 0.5% of the rated full open capacity.

Class III. Intended for the same types of valves as in Class II. Allowable le
limited to 0.1% of rated valve capacity.

Class IV. Intended for single-port and balanced single-port valves with ext
piston seals and metal-to-metal seats. Leakage rate is limited to 0.01% of ra
capacity.

Class V. Intended for the same types of valves as Class IV. The test fluid is
100 psig or operating pressure. Leakage allowed is limited to 5 X 10 ml per
per inch of orifice diameter per psi differential.

Class VI. Intended for resilient-seating valves. The test fluid is air or nitrog
Pressure is the lesser of 50 psig or operating pressure. The leakage limit dep
valve size and ranges from 0.15 to 6.75 ml per minute for valve sizes 1 thro
inches.

XVI

Seat Leakage Classifications


Nominal Port Diameter

Allowable Leakage

(Inches)

(ml Per Minute)

1
1.5
2
2.5
3
4
6
8
10
12

0.15
0.30
0.45
0.60
0.90
1.70
4.00
6.75
9.00
11.5

(*Bubbles Per Minute)


1
2
3
4
6
11
27
45
63
81

*Bubbles per minute as tabulated are a suggested alternative based on a suitable calibrate
measuring device, in this case a 0.25-inch O.D. X 0.032-inch wall tube submerged in wat
depth of from 1/8 to 1/4 inch. The tube end shall be cut square and smooth with no chamf
burrs. The tube axis shall be perpendicular to the surface of the water. Other measuring de
may be constructed and the number of bubbles per minute may differ from those shown a
as they correctly indicate the flow in milliliters per minute.

Note: Provisions should be made to avoid over pressuring of measuring devices resulting
inadvertent opening of the valve plug.
Taken from ANSI B16.104-1976

XVII

Troubleshooting

1. Start with the fail mode of the valve.


A: If the valve fails closed and is leaking...
1. Disconnect the positioner or controller input.
2. If the valve has a hand wheel, check to see that it is backed
out.
3. Check to see if the bench range is correct. Check to see if
there is trash in, or damage to, the valve seat.

2. Next check the positioner


3. Next check the controller.
Do not rely on the control room to generate signals. Generate your
own with equipment that you know is properly calibrated. Do not
assume anything.

Remember that control valves only do what you tell them to.
Many control valve problems turn out to be a problem
somewhere else.

XVIII

Control Valve Terminology


ACTUATOR: A fluid-powered or electrically powered device that supplies force and motion to a VALVE
CLOSURE MEMBER.
AIR SET: Also SUPPLY PRESSURE REGULATOR. A device used to reduce plant air supply to valve
POSITIONERS and other control equipment. Common reduced air supply pressures are 20 and 35 psig.
AIR-TO-CLOSE: An increase in air pressure to the ACTUATOR is required to cause the valve to close.
This is another way of saying the valve is Fail Open or Normally Open.
AIR-TO-OPEN: An increase in air pressure to the ACTUATOR is required to cause the valve to open. This
is another way of saying the valve is FAIL CLOSED or NORMALLY CLOSED.
ANSI: An abbreviation for the American National Standards Institute.
ANTI-CAVITATION TRIM: A special trim used in CONTROL VALVES to stage the pressure drop
through the valve, which will either prevent the CAVITATION from occurring or direct the bubbles that are
formed to the center of the flow stream away from the valve BODY and TRIM. This is usually
accomplished by causing the fluid to travel along a torturous path or through successively smaller orifices or
a combination of both.
API: An abbreviation for the American Petroleum Institute.
ASME: An abbreviation for the American Society of Mechanical Engineers.
ASTM: An abbreviation for the American Society for Testing and Materials.
BALANCED TRIM: A trim arrangement that tends to equalize the pressure above and below the valve
plug to minimize the net static and dynamic fluid flow forces acting along the axis of the stem of a GLOBE
VALVE. Some regulators also use this design, particularly in high pressure service.
BELLOWS SEAL BONNET: A BONNET which uses a BELLOWS for sealing against leakage around
the valve plug stem.
BENCH SET: The proper definition for bench set is the INHERENT DIAPHRAGM PRESSURE RANGE,
which is the high and low values of pressure applied to the diaphragm to produce rated valve plug travel
with atmospheric pressure in the valve body. This test is often performed on a work bench in the instrument
shop prior to placing the valve into service and is thus known as Bench Set.
BODY: The body of the valve is the main pressure boundary. It provides the pipe connecting ends and the
fluid flow passageway. It can also support the seating surface and the valve CLOSURE MEMBER.
BONNET: The bonnet or bonnet assembiy is that portion of the valve pressure retaining boundary which
may guide the stem and contains the PACKING BOX and STEM SEAL. The bonnet may be integral to the
valve body or bolted or screwed. The bonnet, if it is detachable, will generally provide the opening to the
valve body cavity for removal and replacement of the internal TRIM. The bonnet is generally the means by
which the actuator is connected to the valve body.
BOOSTER: A pneumatic relay that is used to reduce the time lag in pneumatic circuits by reproducing
pneumatic signals with high-volume and or high-pressure output. These units may act as volume boosters or
as amplifiers. A 1:2 booster will take a 3 to 15 psig input signal and output a 6 to 30 psig signal. It has also
been shown that a booster may improve the performance of a control valve by replacing a positioner. It can
provide the same stroking speed and can isolate the controller from the large capacitive load of the actuator.
XIX

Control Valve Terminology


BUBBLE TIGHT: A commonly used term to describe the ability of a control valve or regulator to shut off
completely against any pressure on any fluid. Unfortunately, it is completely unrealistic. Control valves are
tested to ANSI B16.104 and FCI 70-2-1976 which is the American National Standard for Control Valve
Seat Leakage. This standard uses 6 different classifications to describe the valves seat leakage capabilities.
The most stringent of these is Class VI which allows a number of bubbles per minute leakage, depending on
the port size of the valve. The correct response to the question "Will that valve go "Bubble Tight"? is to say
this valve is tested to meet Class VI shutoff requirements.
BUTTERFLY VALVE: A valve with a circular body and a rotary motion disk closure member which is
pivotally supported by its stem. Butterfly valves come in various styles including eccentric and highperformance valves. Butterfly valves are HIGH RECOVERY valves and thus tend to induce CAVITATION
in liquid services at much lower pressure drops and fluid temperatures than the globe style valve. Due to
instability problems with the older design butterfly valves, many people will limit the travel of the valve at
60 degrees of rotation on throttling services. This can also help keep the valve out of CAVITATION
problems.
CAGE: A hollow cylindrical trim element that is sometimes used as a guide to align the movement of a
VALVE PLUG with a SEAT RING. It may also act to retain the seat ring in the valve body. On some types
of valves, the cage may contain different shaped openings which act to characterize the flow through the
valve. The cage may also act as a NOISE ATTENUATION or ANTI-CAVITATION device.
CAGE GUIDED VALVE: A type of GLOBE STYLE valve trim where the valve plugs with the seat.
CAVITATION: Occurs only in liquid service. In its simplest terms cavitation is the two-stage process of
vaporization and condensation of a liquid. Vaporization is simply the boiling of a liquid, which is also
known as FLASHING. In a control valve this vaporization takes place because the pressure of the liquid is
lowered, instead of the more common occurrence where the temperature is raised. As fluid passes through a
valve just downstream of the orifice area, there is an increase in velocity or kinetic energy that is
accompanied by a substantial decrease in pressure or potential energy. This occurs in an area called the
VENA CONTRACTA. If the pressure in this area falls below that of the vapor pressure of the flowing fluid,
vaporization (boiling) occurs. Vapor bubbles then continue downstream where the velocity of the fluid
begins to slow and the pressure in the fluid recovers. The vapor bubbles then collapse or implode. Cavitation
can cause a Choked Flow condition to occur and can cause mechanical damage to valves and piping.
CHOKED FLOW: Also known as CRITICAL FLOW. This condition exists when at a fixed upstream
pressure the flow cannot be further increased by lowering the downstream pressure. This condition can
occur in gas, steam, or liquid services. Fluids flow through a valve because of a difference in pressure
between the inlet (Pl) and outlet (P2) of the valve. This pressure difference (Delta-P) or pressure drop
isessential to moving the fluid. Flow is proportional to the square root of the pressure drop. Which means
that the higher the pressure drop is the more fluid can be moved through the valve. If the inlet pressure to a
valve remains constant, then the differential pressure can only be increased by lowering the outlet pressure.
For gases and steam, which are compressible fluids, the maximum velocity of the fluid through the valve is
limited by the velocity of the propagation of a pressure wave which travels at the speed of sound in the fluid.
If the pressure drop is sufficiently high, the velocity in the flow stream at the VENA CONTRACTA will
reach the velocity of sound. Further decrease in the outlet pressure will not be felt upstream because the
pressure wave can only travel at sonic velocity and the signal will never translate upstream. Choked Flow
can also occur in liquids but only if the fluid is in a FLASHING or CAVITATING condition. The vapor
bubbles block or choke the flow and prevent the valve from passing more flow by lowering the outlet
pressure to increase the pres-sure drop. A good Rule Of Thumb on Gases and Steam service is that if the
pressure drop across the valve equals or exceeds one half the absolute inlet pressure, then there is a good
chance for a choked flow condition.
XX

Control Valve Terminology


Example:
P1 100 psig
P2 25 psig
_________
Delta P = 75
P1 (ABS) = 100 + 14.7 or 114.7 1/2 of 114.7 = 57.35
Actual pressure drop = 75
Choked Flow is probable.
The style of valve (that is whether it is a HIGH RECOVERY or a LOW RECOVERY style) will also have
an effect on the point at which a choked flow condition will occur.
CLOSURE MEMBER: The movable part of the valve which is positioned in the flow path to modify the
rate of flow through the valve. Some of the different types of closure members are the Ball, Disk, Gate, and
Plug.
COEFFICIENT FLOW: A constant (Cv) that is used to predict the flow rate through a valve. It is related
to the geometry of the valve at a given valve opening. See Cv.
CONTROL VALVE: Also known as the FINAL CONTROL ELEMENT. A power-operated device used to
modify the fluid flow rate in a process control system. It usually consists of a BODY or VALVE and an
ACTUATOR, which responds to a signal from the controlling system and changes the position of a FLOW
CONTROLLING ELEMENT in the valve.
CONTROL VALVE GAIN: The relationship between valve travel and the flow rate through the valve. It is
described by means of a curve on a graph expressed as an INSTALLED OR INHERENT
CHARACTERISTIC.
CONTROLLER: A device which tells a CONTROL VALVE what to do. Controllers can be either
pneumatic or electronic. There are pressure, temperature, ph, level, differential, and flow controllers. The job
of the controller is to sense one of the above variables and compare it to a set point that has been established.
The controller then outputs a signal either pneumatic or electronic to the control valve, which then responds
so as to bring the process variable to the desired set point.
CRITICAL FLOW: See the definition for CHOKED FLOW.
CV: The VALVE FLOW COEFFICIENT is the number of U.S. gallons per minute of 60 degree F water that
will flow through a valve at a specified opening with a pressure drop of 1 psi across the valve.
DELTA-P: Differential Pressure. The inlet pressure (Pl) minus the outlet pressure (P2).
Example:
P1 = 100 psig
P2 = 25 psig.
___________
Delta-P = 75
DIAPHRAGM: A flexible pressure-responsive element that transmits force to the diaphragm plate and
actuator stem.
DIAPHRAGM ACTUATOR: Is a fluid (usually pneumatic) pressure-operated, spring-opposed diaphragm
assembly which positions the valve stem in response to an input signal.
XXI

Control Valve Terminology


DIAPHRAGM PRESSURE: See Bench Set.
DIAPHRAGM VALVE: A valve with a flexible linear motion CLOSURE MEMBER that is forced into
the internal flow passageway of the BODY by the ACTUATOR. Pinch or Clamp valves and Weir-type
valves fall into this category.
DIRECT ACTING: This term has several different meanings depending upon the device it is describing. A
DIRECT-ACTING ACTUATOR is one in which the actuator stem extends with an increase in diaphragm
pressure. A DIRECT-ACTING VALVE is one with a PUSH-DOWN-TO-C LOSE plug and seat orientation.
A DIRECT-ACTING POSITIONER or a DIRECT-ACTING CONTROLLER outputs an increase in signal
in response to an increase in set point.
DIRECT ACTUATOR: Is one in which the actuator stem extends with an increase in diaphragm pressure.
DUAL SEATING: A valve is said to have dual seating when it uses a resilient or composition material such
as TFE, Kel-F, or Buna-N, etc. for its primary seal and a metal-to-metal seat as a secondary seal. The idea is
that the primary seal will provide tight shut-off Class VI and if it is damaged the secondary seal will backup
the primary seal with Class IV shut-off.
DYNAMIC UNBALANCE: The total force produced on the valve plug in any stated open position by the
fluid pressure acting upon it. The particular style of valve, i.e. single-ported, double-ported, flow-to-open,
flow-to-close, has an effect on the amount of dynamic unbalance.
EFFECTIVE AREA: For a DIAPHRAGM ACTUATOR, the effective area is that part of the diaphragm
area that is effective in producing a stem force. Usually the effective area will change as the valve is stroked
- being at a maximum at the start and at a minimum at the end of the travel range. Flat sheet diaphragms are
most affected by this; while molded diaphragms will improve the actuator performance, and a rolling
diaphragm will provide a constant stem force throughout the entire stroke of the valve.
ELECTRIC ACTUATOR: Also known as an Electro-Mechanical Actuator uses an electrically operated
motor-driven gear train or screw to position the actuator stem. The actuator may respond to either a digital
or analog electrical signal.
END CONNECTION: The configuration provided to make a pressure-tight joint to the pipe carrying the
fluid to be controlled. The most common of these connections are threaded, flanged, or welded.
EQUAL PERCENTAGE: A term used to describe a type of valve flow characteristic where for equal
increments of valve plug travel the change in flow rate with respect to travel may be expressed as a constant
percent of the flow rate at the time of the change. The change in flow rate observed with respect to travel
will be relatively small when the valve plug is near its seat and relatively high when the valve plug is nearly
wide open.
EXTENSION BONNET: A bonnet with a packing box that is extended above the body to bonnet
connection so as to maintain the temperature of the packing above (cryogenic service) or below (high-temp
service) the temperature of the process fluid. The length of the extension depends on the amount of
temperature differential that exists between the process fluid and the packing design temperature.
FACE-TO-FACE: Is the distance between the face of the inlet opening and the face of the outlet opening of
a valve or fitting. These dimensions are governed by ANSI/ISA specifications.
The following Uniform Face-to Face Dimensions apply.

XXII

Control Valve Terminology


SPECIFICATION VALVE TYPE
ANSI/ISA S75.03 INTEGRAL FLANGED GLOBE STYLE CONTROL VALVES
ANSI/ISA S75.04 FLANGELESS CONTROL VALVES ANSUISA S75.20 SEPARABLE FLANGE GLOBE STYLE CONTROL VALVES.

FAIL-CLOSED: Or NORMALLY CLOSED. Another way of describing an AIR-TO-OPEN actuator.


Approximately 80% of all spring return diaphragm operators in the field are of this construction.
FAIL-IN-PLACE: A term used to describe the ability of an actuator to stay at the same percent of travel it
was in when it lost its air supply. On SPRING RETURN ACTUATORS this is accomplished by means of a
LOCK-UP VALVE. On PISTON ACTUATORS a series of compressed air cylinders must be employed.
FAIL-OPEN: Or NORMALLY OPEN. Another way of describing an AIR-TO-CLOSE actuator.
FAIL-SAFE: A term used to describe the desired failure position of a control valve. It could FAILCLOSED, FAIL-OPEN, or FAIL-IN-PLACE. For a spring-return operator to fail-in-place usually requires
the use of a lock-up valve.
FEEDBACK SIGNAL: The return signal that results from a measurement of the directly controlled
variable. An example would be where a control valve is equipped with a positioner. The return signal is
usually a mechanical indication of valve plug stem position which is fed back into the positioner.
F1: Or PRESSURE RECOVERY FACTOR. A number used to describe the ratio between the pressure
recovery after the VENA CONTRACTA and the pressure drop at the vena contracta. It is a measure of the
amount of pressure recovered between the vena contracta and the valve outlet. Some manufacturers use the
therm Km to describe the pressure recovery factor. This number will be high (0.9) for a GLOBE STYLE
VALVE with a torturous follow path and lower (0.8 to 0.6) for a ROTARY STYLE VALVE with a
streamlined flow path. On most rotary products the F1 factor will vary with the degree of opening of the
VALVE CLOSURE MEMBER. Note! F1 does not equal Km.
FLANGELESS: A valve that does not have integral line flanges. This type of valve is sometimes referred
to as a Wafer Style valve. The valve is installed by bolting it between the companion flanges with a set of
bolts or studs called line bolting. Care should be taken that strain-hardened bolts and nuts are used in lieu of
all-thread, which can stretch when subjected to tempera-ture cycling.
FLANGELESS BODY: See FLANGELESS for a definition. This type of valve is very economical from a
manufacturing and stocking standpoint because a valve that is rated as a 600# ANSI valve can also be used
between 150# and 300# ANSI flanges thus eliminating the need to manufacture three different valve bodies
or stock three different valve bodies. The down side is that valves with flangeless bodies are not acceptable
in certain applications - particularly in refinery processes.
FLASHING: Is the boiling or vaporizing of a liquid. See the definition of CAVITATION. When the vapor
pressure downstream of a control valve is less than the upsteam vapor pressure, part of the liquid changes to
a vapor and remains as a vapor unless the downstream pressure recovers significantly, in which case
CAVITATION occurs. Flashing will normally cause a CHOKED FLOW condition to occur. In addition the
vapor bubbles can also cause mechanical damage to the valve and piping system.
FLOW CHARACTERISTIC: The relationship between valve capacity and valve travel. It is usually
expressed graphically in the form of a curve. CONTROL VALVES have two types of characteristics
INHERENT and INSTALLED. The INHERENT characteristic is derived from testing the valve with water
as the fluid and a constant pressure drop across the valve. When valves are installed into a system with
pumps, pipes, and fittings, the pressure dropped across the valve will vary with the travel. When the actual
flow in a system is plotted against valve opening, the curve is known as the INSTALLED flow
XXIII

Control Valve Terminology


characteristic. Valves can be characterized by shaping the plugs, orifices, or cages to produce a particular
curve. Valves are characterized in order to try to alter the valve gain.
Valve gain is the flow change divided by the control signal change. This is done in an effort to compensate
for nonlinearities in the control loop.
FLOW COEFFICIENT: See the definition for Cv.
GAIN: The relationship of input to output. If the full range of the input is equal to the full range of the
output, then the gain is 1. Gain is another way to describe the sensitivity of a device.
GLOBE VALVE: A valve with a linear motion, push-pull stem, whose one or more ports and body are
distinguished by a globular shaped cavity around the port region. This type of valve is characterized by a
torturous flow path and is also referred to as a LOW RECOVERY VALVE because some of the energy in
the flow stream is dissipated; and the inlet pressure will not recover to the extent that it would in a more
streamlined HIGH RECOVERY VALVE.
HANDWHEEL: A manual override device used to stroke a valve or limit its travel. The handwheel is
sometimes referred to as a hand jack. It may be top mounted, side mounted, in-yoke mounted or shaft
mounted and declutchable.
HARD FACING: A material that is harder than the surface to which it is applied. It is normally used to
resist fluid erosion or to reduce the chance of galling between moving parts. Hard facing may be applied by
fusion welding, diffusion, or spray coating the material. Alloy #6 or Stellite is a common material used for
this purpose.
HARDNESS: A property of metals that is discussed frequently when speaking of various component parts
used in valve construction, particularly valve trim. There are two hardness scales which are commonly used,
Rockwell & Brinell.
HARDNESS COMPARISON
ROCKWELL

BRINELL

316 SST

76B

137

17-4 PH

34-38C

352

Hardened Inconel

X-750
38-42C

401

#6 Stellite (Alloy 6)

40-44C

415

Chrome Plating

59-67C

725

Note that 316 SST is on the Rockwell B scale which means it is a much softer material than the others
shown.
HIGH RECOVERY VALVE: A valve design that dissipates relatively little flow stream energy due to
streamlined internal contours and minimal flow turbulence. Therefore, pressure down stream of the valve
VENA CONTRACTA recovers to a high percentage of its inlet value. These types of valves are identifiable
by their straight-th rough flow paths. Examples are most rotary control valves, such as the eccentric plug,
butterfly, and ball valve.
XXIV

Control Valve Terminology


HYSTERESIS: The difference between up-scale and down-scale results in instrument response when
subjected to the same input approached from the opposite direction. Example: A control valve has a stroke
of 1.0 inch and we give the valve a 9 psig signal. The valve travels 0.500 of an inch. We then give the valve
a 12 psig signal, and the valve travels to 0.750 of an inch. When the valve is then given a 9 psig signal, the
stroke is measured at 0.501. That represents hysteresis. Hysteresis can be caused by a multitude of variables,
packing friction, loose linkage, pressure drop, etc. If someone asks you what the hysteresis of your control
valve is, it is a bum question because hysteresis is more aptly applied to an instrument than to a control
valve. There are simply too many variables in the valve and the system to answer the question properly. The
control valve only responds to the controller signal and will move to a position to satisfy the controller - thus
negating the effects of hysteresis.
INCIPIENT CAVITATION: Is a term used to describe the early stages of CAVITATION. At this point
the bubbles are small, and the noise is more of a hiss, like the sound of frying bacon. There is normally no
mechanical damage associated with incipient cavitation although it could have an effect on the corrosive
properties of some fluids.
INHERENT DIAPHRAGM PRESSURE: The high and low values of pressure applied to the diaphragm
to produce rated valve plug travel with atmospheric pressure in the valve body. This is more commonly
referred to as BENCH SET.
INHERENT FLOW CHARACTERISTIC: It is the relationship between valve capacity and valve travel
and is usually expressed graphically. It is derived from testing a valve with water as the fluid and with a
constant pressure drop across the valve. The most common types of inherent flow characteristics are
LINEAR, EQUAL PERCENTAGE, MODIFIED PARABOLIC, and QUICK OPENING.
INSTALLED DIAPHRAGM PRESSURE: The high and low values of pressure applied to the diaphragm
to produce rated travel with stated conditions in the valve body. The "stated conditions" referred to here
mean the actual pressure drops at operating conditions. Example: A control valve may have an INHERENT
DIAPHRAGM PRESSURE or BENCH SET of 8 to 15 psig. But when subjected to a 600 psig. inlet
pressure, it may start to open at 3 psig. and be full open at 15 psig. It is because of the forces acting on the
valve plug and the direction of flow through the valve (FLOW-TO-OPEN or FLOW-TO-CLOSE) that the
installed diaphragm pressure will differ from the inherent diaphragm pressure.
INSTALLED FLOW CHARACTERISTIC: The flow characteristic when the pressure drop across the
valve varies with flow and related conditions in the system in which the valve is installed. The purpose of
characterizing a control valve is to help compensate for nonlinearities in the control loop.
INSTRUMENT PRESSURE: The output pressure from an automatic controller that is used to operate a
control valve. It is the input signal to the valve.
INTEGRAL SEAT: The flow control orifice and seat that is an integral part of the valve body or cage. The
seat is machined directly out of the valve body and is normally not replaceable without replacing the body
itself - although some can be repaired by welding and remachining.
INTEGRAL FLANGE: A valve body whose flange connection is an integral or cast part of the body.
Valves with integral flanges were traditionally known to have the ANSI short FACE-TO-FACE dimension
ANSI/ISA S75.03. However many manufacturers now produce valve bodies with both integral and
SEPARABLE FLANGES that will meet both the ANSI short and long face-to-face dimensions.
I/P: An abbreviation for current-to-pneumatic signal conversion. This term is commonly used to describe a
type of transducer that converts an electric (4-20 m.a) input signal to a pneumatic (3-15 psig.) output signal.
XXV

Control Valve Terminology


LANTERN RING: A rigid spacer used in the packing with packing above and below it. The lantern ring is
used to allow lubrication to the packing or allow access to a leak off connection. On some of the new
fugitive emission packing systems, it also acts as a stem guide.
LAPPED-IN: A term that describes a procedure for reducing the leakage rate on metal-to-metal seated
valves and regulators. The plug and seat are lapped together with the aid of an abrasive compound in an
effort to establish a better seating surface than would normally be achieved by means of machining.
LEAKAGE CLASSIFICATION: A term used to describe certain standardized testing procedures for
CONTROL VALVES with a FLOW COEFFICIENT greater then 0. 1 (Cv). These procedures are outlined in
ANSI Standard d B16.104-1976, which gives specific tests and tolerances for six seat leakage
classifications. It should be remembered that these tests are used to establish uniform acceptance standards
for manufacturing quality and are not meant to be used to estimate leakage under actual working conditions.
Nor should anyone expect these leakage rates to be maintained after a valve is placed in service. There is no
standard test for SELF-CONTAINED REGULATORS at this time. Note! You will see many instances
where regulators are specified using the above criteria.
LEAK-OFF: A term used to describe a threaded connection located on the BONNET of a valve that allows
for the detection of leakage of the process fluid past the packing area.
LINEAR FLOW CHARACTERISTIC: A characteristic where flow capacity or (C v) increases linearly
with valve travel. Flow is directly proportional to valve travel. This is the preferred valve characteristic for a
control valve that is being used with a distributive control system (DCS) or programmable logic controller
(PLC).
LINEAR VALVE: Another name for a GLOBE VALVE. It refers to the linear or straight-line movement
of the plug and stem.
LIQUID PRESSURE RECOVERY: See (F1).
LOADING PRESSURE: The pressure used to position a pneumatic actuator. It is the pressure that is
actually applied to the actuator diaphragm or piston. It can be the INSTRUMENT PRESSURE if a valve
positioner is not used or is bypassed.
LOCK-UP VALVE: A special type of regulator that is installed between the valve POSITIONER and the
valve ACTUATOR, where it senses the supply air pressure. If that pressure falls below a certain level, it
locks or traps the air loaded into the actuator causing the valve to FAIL-IN-PLACE.
LOW RECOVERY VALVE: A valve design that dissipates a considerable amount of flow stream energy
due to turbulence created by the contours of the flow path. Consequently, pressure downstream of the valve
VENA CONTRACTA recovers to a lesser percentage of its inlet value than a valve with a more streamlined
flow path. The conventional GLOBE STYLE control valve is in this category.
MODIFIED PARABOLIC: A FLOW CHARACTERISTIC that lies somewhere between LINEAR and
EQUAL PERCENTAGE. It provides fine throttling at low flow capacity and an approximately linear
characteristic at higher flow capacities.
NORMALLY CLOSED: See AIR-TO-OPEN.
NORMALLY OPEN: See AIR-TO-CLOSE.
XXVI

Control Valve Terminology


P1: Is used to designate Inlet Pressure.
P2: Is used to designate Outlet Pressure.
PACKING: A sealing system that normally consists of a deformable material such as TFE, graphite,
asbestos, etc. It is usually in the form of solid or split rings contained in a PACKING BOX that are
compressed so as to provide an effective pressure seal.
PACKING BOX: The chamber located in the BONNET which surrounds the stem and contains the
PACKING and other stem-sealing components.
PACKING FOLLOWER: A part that transfers a mechanical load to the PACKING from the packing
flange or nut.
PISTON ACTUATOR: A fluid-powered, normally pneumatic device in which the fluid acts upon a
movable cylindrical member, the piston, to provide linear motion to the actuator stem. These units are spring
or air opposed and operate at higher supply pressures than a SPRING RETURN ACTUATOR.
PLUG: See CLOSURE MEMBER.
PORT-GUIDED: A valve plug that fits inside the seat ring, which acts as a guide bushing. Examples:
Splined Plug, Hollow Skirt, and the Feather-Guide Plug.
POSITION SWITCH: A switch that is linked to the valve stem to detect a single, preset valve stem
position. Example: Full open or full closed. The switch may be pneumatic, hydraulic, or electric.
POSITION TRANSMITTER: A device that is mechanically connected to the valve stem and will generate
and transmit either a pneumatic or electric signal that represents the valve stem position.
POSITIONER: A device used to position a valve with regard to a signal. The positioner compares the input
signal with a mechanical feed back link from the actuator. It then produces the force necessary to move the
actuator output until the mechanical output position feedback corresponds with the pneumatic signal value.
Positioners can also be used to modify the action of the valve (reverse acting positioner), alter the stroke or
controller input signal (split range positioner), increase the pressure to the valve actuator (amplifying
positioner), or alter the control valve FLOW CHARACTERISTIC (characterized positioner).
POST GUIDE: A guiding system where the valve stem is larger in the area that comes into contact with the
guide busings than in the adjacent stem area.
PUSH-DOWN-TO-C LOSE: A term used to describe a LINEAR or GLOBE STYLE valve that uses a
DIRECT ACTING plug and stem arrangement. The plug is located above the seat ring. When the plug is
pushed down, the plug contacts the seat, and the valve closes. Note! Most control valves are of this type.
PUSH-DOWN-TO-OPEN: A term used to describe a LINEAR or GLOBE STYLE valve that uses a
REVERSE ACTION plug and stem arrangement. The plug is located below the seat ring. When the plug is
pushed down, the plug moves away from the seat, and the valve opens.
PRESSURE RECOVERY FACTOR: See (F1).
QUICK OPENING: A FLOW CHARACTERISTIC that provides maximum change in flow rate at low travels.

The curve is basically linear through the first 40% of travel. It then flattens out indicating little increase in flow rate as
travel approaches the wide open position. This decrease occurs when the valve plug travel equals the flow area of the
port. This normally happens when the valve characteristics is used for on/off control.

XXVII

Control Valve Terminology


RANGEABILITY: The range over which a control valve can control. It is the ratio of the maximum to
minimum controllable FLOW COEFFICIENTS. This is also called TURNDOWN although technically it is
not the same thing. There are two types of rangeability - inherent and installed. Inherent rangeability is a
property of the valve alone and may be defined as the range of flow coefficients between which the gain of
the valve does not deviate from a specified gain by some stated tolerance limit. Installed rangeability is the
range within which the deviation from a desired INSTALLED FLOW CHARACTERISTIC does not exceed
some stated tolerance limit.
REDUCED TRIM: Is an undersized orifice. Reduced or restricted capacity trim is used for several reasons.
(1) It adapts a valve large enough to handle increased future flow requirement with trim capacity properly
sized for present needs. (2) A valve with adequate structural strength can be selected and still retain
reasonable travel vs. capacity relationships. (3) A valve with a large body using restricted trim can be used
to reduce inlet and outlet fluid velocities. (4) It can eliminate the need for pipe reducers. (5) Errors in over
sizing can be corrected by use of restricted capacity trim.
REVERSE ACTING: This term has several deferent meanings depending upon the device it is describing.
A REVERSE-ACTING ACTUATOR is one in which the actuator stem retracts with an increase in
diaphragm pressure. A REVERSE-ACTING VALVE is one with a PUSH-DOWN-TO-OPEN plug and seat
orientation. A REVERSE-ACTING POSITIONER or a REVERSE-ACTING CONTROLLER outputs a
decrease in signal in response to an increase in set point.
REVERSE FLOW: Flow of fluid in the opposite direction from that normally considered the standard
direction. Some ROTARY VALVES are considered to be bi-directional although working pressure drop
capabilities may be lower and leakage rates may be higher in reverse flow.
ROTARY VALVE: A valve style in which the FLOW CLOSURE MEMBER is rotated in the flow stream
to modify the amount of fluid passing through the valve.
SEAT LOAD: The contact force between the seat and the valve plug. When an actuator is selected for a
given control valve, it must be able to generate enough force to overcome static, stem, and dynamic
unbalance with an allowance made for seat load.
SEAT RING: A part of the flow passageway that is used in conjuction with the CLOSURE MEMBER to
modify the rate of flow through the valve.
SELF-CONTAINED REGULATOR: A valve with a positioning actuator using a self-generated power
signal for moving the closure member relative to the valve port or ports in response and in proportion to the
changes in energy of the controlled variable. The force necessary to position the CLOSURE MEMBER is
derived from the fluid flowing through the valve.
SEPARABLE FLANGE: Also known as a SLIP-ON FLANGE. A flange that fits over a valve body flow
connection. It is generally held in place by means of a retaining ring. This style of flange connection
conforms to ANSI/ISA 275.20 and allows for the use of different body and flange materials. Example: A
valve with a stainless steel construction could use carbon steel flanges. This type of valve is very popular in
the chemical and petro-chemical plants because it allows the use of exotic body materials and low cost
flanges.
SOFT SEATED: A term used to describe valve trim with an elastomeric or plastic material used either in
the VALVE PLUG or SEAT RING to provide tight shutoff with a minimal amount of actuator force. A soft
seated valve will usually provide CLASS VI seat leakage capability.

XXVIII

Control Valve Terminology


SPLIT BODY: A valve whose body is split. This design allows for easy plug and seat removal. Splitbodied valves are made in both the straight-through and angle versions. The Masoneilan 2600 or ANNIN is
an example of a split body valve.
SPRING RATE: A term usually applied to SELF-CONTAINED REGULATORS describing the range of
set point adjustment available for a particular range spring.
STATIC UNBALANCE: The net force produced on the valve stem by the fluid pressure acting on the
CLOSURE MEMBER and STEM within the pressure retaining boundary. The closure member is at a stated
opening with a stated flow condition. This is one of the forces an actuator must overcome.
STELLITE: Also called #6 Stellite or Alloy 6. A material used in valve trim known for its hardness, wear
and corrosion resistance. Stellite is available as a casting, barstock material and may be applied to a softer
material such as 316 stainless steel by means of spray coating or welding.
STEM: The VALVE PLUG STEM is a rod extending through the bonnet assembly to permit positioning of
the plug or CLOSURE MEMBER. The ACTUATOR STEM is a rod or shaft which connects to the valve
stem and transmits motion or force from the actuator to the valve.
STEM GUIDE: A guide bushing closely fitted to the valve stem and aligned with the seat. Good stem
guiding is essential to minimizing packing leakage.
SUPPLY PRESSURE: The pressure at the supply port of a device such as a controller, positioner, or
transducer. Common values of control valve supply pressures are 20 psig. for a 3-15 psig. output and 35
psig. for a 6-30 psig. output.
STROKE: See TRAVEL.
THROTTLING: Modulating control as opposed to ON/OFF control.
TRANSDUCER: An element or device which receives information in the form of one quantity and coverts
it to information in the form of the same or another quantity. (See I/P)
TRAVEL: The distance the plug or stem moves in order to go from a full-closed to a full-open position.
Also called STROKE.
TRIM: Includes all the parts that are in flowing contact with the process fluid except the body, BONNET,
and body flanges and gaskets. The plug, seats, stem, guides, bushings, and cage are some of the parts
included in the term trim.
TRUNNION MOUNTING: A style of mounting the disc or ball on the valve shaft or stub shaft with two
bushings diametrically opposed.
TURNDOWN: A term used to describe the ratio between the minimum and maximum flow conditions seen
in a particular system. Example: If the minimum flow were 10 G.P.M. and the maximum flow were 100
G.P.M. the turndown would be 10:1. This term is sometimes incorrectly applied to valves. See
RANGEABILITY.
VALVE: A device which dispenses, dissipates, or distributes energy in a system.
VALVE BODY: See BODY.
VALVE FLOW COEFFICIENT: See Cv.
VALVE PLUG: See CLOSURE MEMBER.
VENA CONTRACTA: The location where cross-sectional area of the flow stream is at its minimum size,
where fluid velocity is at its highest level, and where fluid pressure is at its lowest level. The vena contracta
normally occurs just downstream of the actual physical restriction in a control valve.
XXIX

"Tips & Tricks"


1. If you are dealing with a corrosive fluid, choose the valve body and trim material to
match the pump casing and impeller.
2. Velocity is the key to handling abrasive materials. Normal city water velocity is
about 7 to 10 F.P.S. (clean liquid). If you have a fluid that is abrasive, keep the
velocity as low as possible - without having the particles drop out of suspension.
3. Always sense pressure where you want to control it. Many control valves and
pressure regulators do not function properly simply because they are sensing pressure
at one point and being asked to control it somewhere else.
4. Velocity is the key to handling noise. Noise is energy. When dealing with high
pressure drop situations try always to keep the velocities below 0.3 mach. on the inlet
pipe, valve body, and outlet pipe.
5. If you use a transducer in a control loop, specify a positioner on the valve.
Otherwise the transducer will rob the actuator of available thrust, and the valve will
leak when it is supposed to shut off.
6. In cavitating fluids - even if the control valve has cavitation trim in it - be sure to
allow a straight run of downstream pipe after the valve. If there is a pipe "T" or
elbow immediately downstream, the flow will choke out and back up into the valve.
7. If you use a control valve with a bellows seal in it, try to size the valve so that its
normal throttling position is near the bellows "at rest" position. This will minimize
wear on the bellows.
8. Don't use a valve below 10% of flow if at all possible. Even though a valve may have
good rangeability, if the valve is used in an abrasive or erosive service (steam), it will
not hold up unless it has hardened trim.
9. If a PLC is being used to control the valves in a system, specify the valves with a
linear flow characteristic.
10. If a control valve is started up and fails to respond - or goes to full open or full
closed and stays there - check the controller and reverse the controller's action.

XXX

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