SAMSON

Control valves Fundamentals

Control valves
IEC 534 Part 1 defines a control valve as " A power-operated device forming a final element in an industrial process control system. It consists of a body subassembly containing internal means for changing the flow rate of the process fluid. The body subassembly is linked to one or more actuators which respond to a signal transmitted from a controlling element. " Automatic operation The control valve is operated by means of an analog or digital controller or a PC-based process control system. Manual operation The control valve is operated using a remote adjuster or a handwheel Control valves are operated continuously and, if need be, opened or closed by a higher-level safety control system.
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Control valves
The control valve ... is part of the automation system. is a component of the processing plant. is subject to design and operation regulations for pipelines and pressure vessels. must show low-maintenance features since the points of installation are distributed all over the processing plant and often difficult to access.

The valve is used in all kinds of processing plants and, hence, comes into contact with all types of matter, such as aggressive gases, vapors and liquids under varying operating conditions. Environmental considerations as well as the customers demand low noise emission and very often tight shut-off of the process medium.
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Control valves
The control valves used for fluids are linear valves as well as valves with rotating closure members, such as butterfly, ball and rotary plug valves. The control valves used in processing plants are mostly linear valves. Control valves and shut-off valves have uniform installation dimensions. This allows valves from different vendors and in different versions to be exchanged easily. The general designations comply with international standards. Control valves largely comply with DIN 2401 and DIN 2402, hence, with the basic pipeline standards.

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Valve styles

Globe valves

Three-way valves as mixing valve or diverting valve

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Valve styles

Butterfly valves

Rotary plug valves

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Direction of flow

In linear valves, the direction of flow always opposes the closing direction of the plug If the direction of flow is the same as the closing direction of the valve, instabilities are caused when controlling around the closing point.

Closing direction

Direction of flow

A suction forms at the plug trying to pull it into the seat.

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Direction of flow

In three-way valves, the direction of flow always opposes the closing direction of the plug. Direction of flow It must be taken into account whether the three-way valve is used for mixing or diverting service.

Closing direction

Closing direction

Diverting valve
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Technical data
Apart from the valve style, the following technical data are important. They always have to be indicated in the order:

Nominal size DN and type of connection (valves with screwed ends, valves with flanges).
Nominal pressure PN resulting from the operating pressure and the operating temperature. Permissible differential pressure Dp Flow coefficient: Kvs Control valve characteristics (abbreviations: GN = equal percentage LN = linear)
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Nominal size [DN]

The nominal size DN (DN 15, 20, 25, 32, 40, 50, 65, 80...) is usually identical with the size of the pipe. One nominal size is assigned to several Kvs values.

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Nominal pressure [PN]

Nominal pressures PN16, PN25, PN40, PN65, PN100 ... are stated in gauge pressure (bar or pa) 1 bar = 100 000 pa The nominal pressure of cast iron corresponds to the prevailing operating pressure for temperatures up to 120 C. Material: cast iron
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Nominal pressure [PN]

Note: Different materials produce different characteristics at operating temperature!

Material: spheroidal graphite iron

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Pressure ratios within the system

An easy example

Valve

The heating system in which the pressure prevails includes:

Heat generator Pump Valve Heat consumer

Pump

Consumer

Heat generator

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Pressure development in a pipeline

Three different valve positions

Pipeline

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Reductions in cross section

Cross-sectional reductions lead to a higher velocity of the medium ... across pipe reductions

across throttling areas w1 , w 2 velocities

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Stream profiles

Flow ...

across large cross sections causes low internal friction.

across small cross sections causes high internal friction.

Large cross section = Small difference in velocity

Small cross section = Large difference in velocity

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Flow rate depending on Dp

Tank filled with a liquid that can flow out through a hole:

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Flow equation
In practice, the measurable flow across a control valve turns out to be slightly smaller than the theoretical value calculated by means of a previously derived equation. This is caused by the following: Style of the control valve Ratio of opening between the control valve inlet and outlet (with reducers and increasers) Viscosity of the medium (-> Reynolds number) Amount of pressure recovery Expansion of compressible media Flow limitation of liquids

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Definition of Kv value
To be able to compare different types of control valves, a uniform procedure for measuring the flow rate (IEC 534, Part 4) has been agreed upon.

The Kv (Kvs) value of a control valve considers the influence factors mentioned above and is determined by:
Water as medium Density of 1000 kg/m3 Temperature of 5 to 50 C Differential pressure of 1 bar

The Kvs value is a value which results from the operating conditions stated above when the valve has reached the rated travel (=100%).

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Pressure development in the valve

P1 p2 pvc pv Upstream pressure Downstream pressure Lowest static pressure in the valve Saturated steam pressure of the medium

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Types of flow
Laminar flow No exchange between the molecules of a liquid in the flow laminar

Turbulent flow Immediate exchange between the molecules of a liquid in the flow

turbulent
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Working equations

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Details from a specification sheet

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Valve characteristics
Equal percentage Often logarithmic representation Linear Plotted rangeability: Smallest flow rate to be controlled : Largest flow rate to be controlled 50 : 1

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