CONTROL VALVES

Presented By:Jyoti Ranjan Naik Souraj Ranjan Patel Dhiren Mohapatra Umasankar Paragniha Santram Kumhar Kulamani Barik

Guided By:Mr. Rakesh Yadav (Junior Manager, Instrumentation)

CONTROL VALVE

A CONTROL VALVE IS A FINAL CONTROL ELEMENT AND A POWER OPERATED DEVICE WHICH MODIFIES THE FLOW RATE IN A PROCESS CONTROL SYSTEM. TO DO THIS THE VALVE MUST:

Cont.

Contain the fluid without external Leakage. Have adequate capacity for the intended service Be capable of withstanding the erosive, corrosive, and temperature influences of the process Appropriate end connections to mate with adjacent pipelines

ROLE OF A CONTROL VALVE

It is used for The correct distribution and control of Flowing fluid or gases Reduction of Pressure As a variable orifice As a throttling or modulating equipment

CONTROL VALVE PARTS

1. BODY 2. VALVE 3. ACTUATOR

BODY

The body is the pressure carrying part and it meets all their applicable pressure, temperature and corrosion requirements.

THE BODY PROVIDES THE PIPING CONNECTING ENDS FLUID FLOW PASSAGE WAY, AND SUPPORT THE SEATING SURFACE THE VALVE CLOSURE MEMBER

BODY- INTERNAL PARTS

GLAND PACKING

BODY FLANGE STEM WITH PLUG

INLET

OUTLET SEAT

ACTUATOR

ACTUATOR

UTILISES AIR PRESSURE / ELECTRIC POWER . HYDRAULIC PRESSURE TO ACT ON A DIAPHRAGM / PISTON AND DEVELOP A FORCE TO MOVE THE ACTUATOR STEM

ACTUTATOR CLASSIFICATION

PNUEMATICALLY OPERATED DIAPHARGM ACTUATOR PNUEMATICALLY OPERATED CYLINDER ACTUATOR MOTOR OPERATED PISTON ACTUATOR HYDRAULIC OPERATED PISTON ACTUATOR

ACTUATOR PARTS
VENT DIAPHRAGM DIAPHRAGM CASINGS ACTUATOR

PLATE
DIAPHRAGM INPUT SIGNAL

SPRING ACTUATOR STEM

SPRING SEAT YOKE STEM CONNECTOR INDICATOR GLAND STUDS SCALE SPRING ADJUSTER

LOCK NUT
BONET FLANGE

STUFFING BOX

YOKE
.

A STRUCTURE BY WHICH THE DIAPHRAGM ASSEMBLY IS SUPPORTED RIGIDLY ON THE BONNET ASSEMBLY

YOKE
ACTUATOR BASE SPRING ADJUSTMENT SPRING BASE NUT STEM COUPLING POINTER TRAVEL SCALE BONNET BASE

TRIM

The trim of the valve consists of all the parts which will be wetted other than the body and the bonnet Trim is the heart of the valve with a primary function to proportion the valve orifice in such a manner that a prescribed relationship exists between flow capacity and valve plug lift The secondary function may be shut off tightly.

The trim includes Seat, Plug, Stem, Gland Follower, Gland Nut, Plug, Guide Bushings and Cage Stuffing box components considered as trim are the packing, follower, Spring, Lantern Ring, and Packing Retaining Ring. Secondary trim parts are stem to plug attachments , seat retaining ring, seat to body seals and spacers.

Types Of Control valves

Types Of Control valves

Manual

Motorized

Hydraulic

Pneumatic

Power Cylinder Damper

Valve

Single Acting

Double Acting

Ball, Gate, Butterfly, etc.

ATO/ATC

Hydraulic operated Valve:A fluid or oil is used to operate this valve. Pneumatic operated Valve:Operating fluid is compressed air. Manual operated Valve:Operated by human with the help of lever Electrically operated valve. Solenoid operated Valve:Operated electromagnetically through supply of 0-24 volt dc. Motorized operated Valve:operated through electrical motors such as servo motor.

Globe valve:
Disc or plug moved perpendicular to flow and closes on

a ring seat
Throttling, general purpose flow control valve
Advantages faster than gate, seat less

Wear and tear, high pressure drop for pressure control.

Disadvantage high pressure drop,

require considerable power to operate (gears and levers), heavy

Butterfly Valve
Rotating disk on a shaft, in a housing

Low pressure, large diameter lines where leakage is unimportant Advantages low pressure drop, small and light weight
Disadvantages high leakage, high actuation forces so limited to low pressures

Gate Valve
Sliding disk, perpendicular to flow Applications: Stop valves, (not throttling), high pressure and temp, not for slurries, viscous fluids Advantages low pressure

drop when fully open, tight seal when closed, free of contamination buildup
Disadvantages vibration when partially open, slow response and large

actuating force

Gate Valve

Ball Valve
FEATURES Oldest of all valves, applied for wide range of application. APPLICATION Pressure control , flow control & shut off application . Can be used for corrosive fluids Used for high temp application, LPG application. ADVANTAGES Low pressure drop Tight shut off. Quarter turn application. Small in size & lighter in weight. DISADVANTAGES Cannot be used for throttling application. Fluid trapped in ball may cause corrosion.

Ball Valve

Needle valve

Its having a small part and a threaded needle shaped plunger Used in flow metering application specially when a constant calibrated low flow rate must be maintained for some time Its cannot be used in simple shut off valve because of slow operation It has tight leakage proof closing.

Types of valves used in NECO

AIR TO OPEN (Normally closed, Forced to open) AIR TO CLOSE (Normally open, Forced to Close)

Used at.
CCM :-

Primary & secondary cooling- Air to close (ATC) Co jet:-

In O2, Propane gas, cooling water line- ATO V.D.- Air to open (ATO) Turbine:_ Gland steam, PRDS, hotwell, Desuperheater- ATO Boiler:For oil line ATO Temperature, Steam pressure control v/v. - ATO

Components In C.V.

Positioner Air filter regulator Current to pressure converter i.e. (I/P) Air lock Relay Feedback transmitter

Positioner
A positioner is a device put into a valve to ensure

that it is at a correct position of opening as per the control signal. Works on the principle of force balancing (spring force and valve force). Positioner senses the valve opening through a position feedback link connected to valve stem which is its input signal. I/P converter output is its set point input. Hence positioner is nothing but a pneumatic feedback controller.

Air Filter Regulator

Air filter regulator regulates the input pressure of

the air into the desired output. And secondarily filters the moisture, foreign particles etc in supply air.

Current to Pressure converter

Instrument used to transmit dc mA input signal to

pneumatic signal. Its works on the process of magnetization. Its basic components in I/p converter of I.L. is flapper, nozzles, permanent magnet, coil. Input- 4 20 mA.
Output- 0.2 1 kg/cm^2.

I/P Converter

Air Lock Relay

Its a reliable unit for achieving stay put condition

of control valve on air supply failure It is similar to the non returning valve. When the supply pressure falls below the set value it comes into action The set up value is generally higher than that of the operational valve. Its setup value is given by the compressing the spring by spring adjusting screw.

Feedback transmitter

It works on the principle of potentiometer. It provides the feedback of the valve position and helps positioner in the error correction. Its is connected to the stem of the valve and through its up and down movement its gives the feedback. Potentiometer is a variable resistance measuring device.,

Calibration Of Control Valve

Calibration is a comparison between measurements one of known magnitude or correctness and the other is of unknown correctness. The device with the known or assigned correctness is called the standard. The second device is the unit under test or test instrument.

DCS Signal

0.2 to 1 kg/cm^2
I to P

Air supply at
6 kg/cm^2

Positioner

Converter

AFR 1

AFR 2
Air at a pressure 3.5 kg/cm^2

Master Cylinder

0.2-1 kg/cm^2

AFR 1

Air supply at 6 kg/cm^2

AFR 2
Air at a pressure 3.5 kg/cm^2

PROCEDURE

To calibrate a valve first check the input signal range if it is 0.2 to 1.0 Kg/cm2 or different. Calculate the span ( Difference between higher limit to lower limit=1.0-0.2=.8 ) Now divide it in four equal parts that is 0.2 Kg/cm2 this is 25% of the span. Now check the valve travel like 2 inches, 3 inches or any other value Divide it in four equal parts 25% of the travel.

Apply 25% of the span value+ 0.2= 0.4 Kg/cm2 it is 25% of travel and apply full span value and see you get the complete travel if you find difference adjust the spring accordingly. We can also use DCS for calibration by sending signal i.e. current(4-20 mA) and can detect the % of valve opening.

Data Required For Calibration

PRESSURE (kg/cm^2) 0.2 0.4 CURRENT (mA) 4 8 % OF VALVE OPENING 0 25

0.6
0.8 1

12
16 20

50
75 100

Problems in Control valve

Moisture problem in AFR. Filter chocking Calibration linearity error. Valve components failure Positioners cam wheel rusting & cam misalignment

Shutoff valve

It is a digital way of valve which works either for full opening or closing i.e. 0 or 100% Its used for safety purpose and also in emergency conditions. It is generally operated by solenoid valve which pneumatically operates the power cylinder or diaphragm valves. In simple shutoff valve generally needle valve is not used.

Advantages of Shut off valve

Quicker in operation. Low in cost. Can be operated with small effort. More accurately the flow can be controlled. Less chances of human error. Many valves can be operated simultaneously at a time. Tight shut off. Heavy wall can be easily operated.

Limitation:

It Can Only Operate Either 0 or 100% It Cant be used for throttling action

QUERIES If ANY?