CONTROL VALVE

Process Control

Valve Terminology
a body design in which the same pressure acts on both sides of the valve plug, thus reducing the actuator force required to open the valve. This characteristic is available in single port valves. Bellows seal : a physical barrier or seal which uses a bellows for sealing against leakage around the valve plug stem. Bonnet assembly: an assembly including the part through which a valve plug stem moves and a means for sealing against leakage along the stem. It usually provides a means for mounting the actuator.
Balanced valve:
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Valve Terminology
Capacity: rate of flow through a valve under stated conditions. Cavitate: the formation and subsequent collapse of voids or cavities in a valve resulting from increased fluid velocity through the restricted areas of the valve. It occurs in liquids when the valve operates near the vapor pressure of the liquid. Characteristic: relation between flow through the valve and percent rated travel as the latter is varied from zero to 100%.

Control Valve

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Valve Terminology
Corrosion: the reactions between materials of the valve and the fluids handled which cause valve deterioration. Dead band : the amount the diaphragm pressure can be varied without initiating valve plug motion.

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Double Acting Position Actuator

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Valve Terminology
Equal percentage flow characteristic: an inherent flow characteristic which, for equal increments of rated travel, will ideally give equal percentage changes of the existing flow. Erosion: A wearing action on valve trim and body, resulting from high velocity fluids and fluids containing solids particles, it is prevalent in steam service, in flashing service, in some chemical services and where high pressure drops occur. Extension bonnet : a bonnet with an extension between the packing box assembly and bonnet flange. Flow characteristic: see Characteristic Flow coefficient: see C. Galling : a high friction condition between the valve stem and stem guides, bushings or packing, resulting from a lack of lubricity between the moving parts.

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Valve Characteristics

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Valve Terminology
Guide bushing : a bushing in a bonnet, bottom flange or body to align the movement of a valve plug with a seat ring. High recovery characteristic: a term applied to the design characteristic of a valve which allows a high percentage ratio of downstream to upstream pressure. Inherent flow characteristic : flow characteristic when constant pressure drop is maintained across valves. Inherent rangeability: ratio of maximum to minimum flow within which the deviation from the specified inherent flow characteristic does not exceed some stated limits. Installed flow characteristic: an inherent flow characteristic which can be represented ideally by a straight line on a rectangularly plot of flow versus percent rated travel. Leakage: quantity of fluid passing through an assembled valve when valve is in fully closed position under stated closure forces, with pressure differential and temperature as specific.

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Valve Terminology
Linear flow characteristic: an inherent flow characteristic which can be represented ideally by a straight line on a rectangular plot of flow versus percent rated travel Low recovery characteristic: a term applied to the design characteristic of a valve which causes a low percentage ratio of downstream to upstream pressure. Modulate: the function of a controller which causes a valve to respond to an infinite number of positions between the closed and full open positions. Normally closed: applying to a normally closed control valve assembly, one which closed when the actuator pressure is reduced to atmospheric. Normally open: applying to a normally open control valve assembly, one which opens when the actuator pressure is reduced to atmospheric.
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Valve Terminology
P : the pressure drop across a valve. The condition must be specified. For example: P for sizing; P at normal flow; P at valve closure; etc. Packing box assembly: the part of the bonnet assembly used to seal against leakage around the valve-plug stem, including various combinations of all or part of the following : packaging, packing nut, packing follower, lantern ring, packing spring, packing flange, packing flange studs or bolts and packing flange nuts. Plug : a moveable part which provides a variable restriction in a profile. Rangeability: the ratio of maximum to minimum usable sizing coefficient. Rated C : the value of C at the rated full open position. Rates travel: linear movement of the valve plug from the closed position tot the rated full open position. Seat: that portion of a seat ring or valve body which a valve plug contacts for closure. Seat ring: a separate piece inserted in a valve body to form a valve body port.

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Valve Terminology
Stem: a rod extending through the bonnet assembly to permit positioning the valve plug. Trim: the parts except the body of a valve which come into contact with the flowing fluid. Turndown: the ratio of maximum to minimum flow requirements. Valve body: a housing for internal valve parts having inlet and outlet flow connections. Valve characteristics: see Characteristic Valve plug: see plug Valve plug guide: that portion of a valve plug which aligns its movement in either a seat ring, bonnet, bottom flange or any two of these. Valve stem; see Stem. Yoke: a structure by which the diaphragm case assembly is supported rigidly on the bonnet assembly.

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Classification
Control valve is defined as continuous varying orifice in fluid flow line They change the value of the variable by changing the rate of flow In most applications it is the final control element. It provides the power to translate the controller output to the process either by
Two position on-off or Proportional (throttling)
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General Control Valve Assembly

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Valve Body Assembly

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Extension Bonnet
Bonnet assembly: an assembly including the part through which a valve plug stem moves and a means for sealing against leakage along the stem. It usually provides a means for mounting the actuator. A bonnet with greater dimension between the packing box and bonnet flange for hot or cold service

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Bellows Seal Bonnet

Bellows seal : a physical barrier or seal which uses a bellows for sealing against leakage around the valve plug stem. It is mainly used in toxic applications.

Control Valve

Direct Acting Actuator

Process Control

Control Valve

Reverse Acting Actuator

Process Control

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Valve Selection
Process requirements
Inlet and differential pressure across the valve. Maximum and minimum flow The flowing temperature The degree of shutoff

Correct valve sizing to handle its maximum design flow at 75% fully open. Typically the valve should not operate
below the 10% opened position or above the 90% open position
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Valve Selection
Suitable flow characteristics of the valve to match the process requirements :
Linear Equal percentage Quick opening

Fail safe mode on air and signal failure

Fail-closed valve (FC) will have a spring that closes the valve on air failure Fail-open mode will have a spring that opens on air failure
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Valve Pressure Drop

Valve type Globe full trip Globe reduced trip Ball full bore Butterfly 60 open Butterfly 90 open Equivalent length of straight pipe in pipe diameter 350 1100 4 120 29

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Installation Notes
Always refer to vendor recommendations. During pipe pressure testing the valves should be kept fully open to avoid high differential pressure across the valve. Pipe on either side of the valve should be supported. It is good practice to allow 5 pipe diameters upstream and down stream from the valve to minimize to minimize disturbance. If there is space limitation allow as a minimum.

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Rules of Thumb
Globe valves are used for up to 3 inch lines Globe, ball, and eccentric rotary plug valves for 3 to 6 inches Rotary valves for 6 to 12 inch Butterfly valves for larger than 12 inch. To avoid corrosion problems cast iron and bronze bodies are used for air, steam and water only. For all other conditions the body and trim material must meet the process conditions.

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Globe Valve
They are ideal for high-pressure drop application They are available with either single or double seated construction

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Single Seated Globe Valve

Single-seated
1. Used on all 1 in (25mm) Smaller valves 2.Top guided

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Double Seated Globe valve

Double-seated
Advantage
1. Require Less actuator forces 2. Top and bottom guided

Disadvantage
1. Expensive 2. Difficult to service, maintain and adjust and does not provide tight shutoff

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Three-way Glove Valve

Three-way globe valves
Have a linear characteristics, they are an extension of typical double-seated globe

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Diaphragm Valve
Diaphragm valves are operated by forcing a flexible diagram against a bridge or weir to stop the flow

There is tow types of diaphragm valve

Weir -type

1. Lasts longer than the straight-through type 2. Has less flow capacity

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Diaphragm
Straight-through
1. Best suited for slurries 2. Has lower dp rating than the weir design
These valves are excellent for liquids that containing solids or dirt These valves are low cost and their maintenance is simple However they have poor flow characteristics, due to their application in slurry service they tend to be a high-maintenance item

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Diaphragm Valve

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Ball valve
The ball valve is a rotary-action valve The ball valve has greater capacity and lower cost than a similar-size globe valve The full-bore ball valve is used for on/off only and not in control application, it have a bad response for the first 30% of its travel, but will operate at a higher dp . The characterized ball valve consist of a partial sphere when opening up , presenting a triangle form that makes it suitable for liquids with solids.

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Ball valve
This valve is less expensive, lighter, and easier to install and maintain than the globe valve Variation of ball valve provide the plug valve, but with linear or equal percentage characteristics and 1:10 to 1:100 rangeability Ball valve are good for fluids with suspended solids, due to their straight-through and self-cleaning ,they have low weight, simple in design and minimum effect of corrosion

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Butterfly Valve
Consists of a cylindrical body with a disk mounted on a shaft and rotating perpendicular to axis of valve body It also have a large capacities, the only obstruction to the flow is the disk The torsional force of the shaft increase until it reach 70 to 75 after that it tend to decrease It has low cost , small body ,easy to install ,minimum corrosion ,butt however limited pressure control range ,low use in noise application and can not use in dirty fluids

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Conventional Disk Butterfly Valve

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Contoured Disk Butterfly Valve

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Eccentric Disk Control Valve

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Eccentric Rotary Plug

Provide an eccentric motion that produce performance and capacity close to globe valve Have operating stroke 50 Metal to metal seating provide good shut off It have height capacity, reasonable cost , low actuating forces. Has the tendency to cavitate and highpressure recovery.

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Eccentric Rotary Plug

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Valve Petitioners
A valve positioner is in reality an actuator positioner. A valve positioner is basically a relay that senses both an instrument signal and a valve stem position. Positioners are typically supplied with 3 pressure gauges:
Supply Input Output

Effectively it may be described as a closed-loop controller that has the instrument signal as input, an output to the valve diaphragm and feedback from the valve stem.
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Valve Positioner
Provide accurate positioning of valve stem Change control valve characteristics Increase valve speed of response Reverse valve action (direct or reverse) Increase shutoff rating To control spring less actuators (double acting positions)

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Valve Positioner
The valve positioner consists basically of:
A bellow to receive the instrument or controller signal A beam fixed to the bellow at one end and through linkage to the valve stem at the other end. A relay whose nozzle forms flapper nozzle arrangement with beam.

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Valve Positioner Operation

As the bellow moves in response to a changed instrument signal, the flapper nozzle arrangement moves either admitting air to the diaphragm unit or bleeding air from it until the valve stem position correspond to the instrument air signal. At this point, the positioner is once again at equilibrium with the changed instrument signal.

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Positioner for Diaphragm Actuator

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Electro-Pneumatic Positioner

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Electro-Pneumatic Positioner

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Positioners

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Positioners
Motion Balance

Figure shows a schematic of a motion balance positioned, and its physical appearance is seen in Figure. It consists basically of (a) a bellows to receive the instrument signal, (b) a beam fixed to the bellows at one end and, through linkage, to the valve stem at the other end, and (c) a relay whose nozzle forms a flapper-nozzle arrangement with the beam. As the bellows moves in response to a changed instrument signal, the flapper-nozzle arrangement moves, either admitting air to, or bleeding air from, the diaphragm until the valve stem position corresponds to the instrument air signal. At this point the positional is once again in equilibrium with the changed instrument signal.

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Positioners

Force Balance A force balance positioner is shown in Figure. The output pressure from a controller is applied to the bellows (12) of the positioner. For any given controller output, there is a corresponding position of the controlled element (in this case, a cylinder). At the slightest change in signal pressure, full supply pressure is available to ensue immediate and accurate positioning of the cylinder.

Control Valve