CONTROL VALVE APPLICATION

What is a Control Valve ? Control Valves are one type of the final control element in a open or closed Control Loops.

Common Terms used in Control Valve

1. Flow Coefficient (Cv or Kv)
Cv is defined as Quantity of water in US GPM, at 60 Deg F, that will flow thru the valve At specified travel with pressure drop of 1 psig. Cv is the term used in US. Kv is defined as Quantity of water in m3/Hr, at 5 Deg C and 40 Deg C, that will flow thru the valve at specified travel with pressure drop of 1 barg. Kv is the term used in Europe. Relationship between Cv and Kv is : Kv = 0.856 Cv

Common Terms used in Control Valve

2. Dead Band
The range thru which an output signal can be varied, upon reversal of signal, without initiating observable change in output. For the valve assembly, controller output is input to valve assembly and process variable is Output. Dead band is expressed as percentage of input band.

3. Hysterisis
Maximum difference in output value for any single input value during a calibration cycle, excluding errors due to dead band

Common Terms used in Control Valve

4. Inherent Flow Characteristics
The relationship between Flow Coefficient and the closure member (disk) travel as it is moved from closed position to rated valve travel with constant pressure drop across the valve.

Common Terms used in Control Valve

4. Inherent Flow Characteristics
Linear Characteristics : Travel is linearly proportional to capacity and therefore the theoretical Gain is constant at all loads. Equal Percentage Characteristics : A unit change in lift will result in a change in flow rate, which is Is a fixed percentage of the flow rate at that lift. E.g. each %age increase in lift will increase the previous flow rate by about 3%. Therefore, theoretical gain of equal percentage valves is directly proportional to flow rate and increases as the flow rate increases On logarithmic chart, the equal percentage characteristics correspond to a straight line having a slope that corresponds to its fixed percentage. Quick Opening Characteristics : The gain decreases with increase in flow rate.

Common Terms used in Control Valve

5. Installed Flow Characteristics
When the valves are installed in process, the differential pressure is no longer constant, it varies With flow. The differential pressure drops as the flow increases, Valve gain also drops, this tends to shift the Characteristics of the equal percentage valve to linear and installed linear valve to quick opening.

6. Rangeability
Ratio between maximum and minimum controllable flow thru the valve. OR Ratio of the Cv required at maximum flow (and minimum pressure drop) and the Cv required at minimum flow (and maximum pressure drop).

Common Terms used in Control Valve

7. Fast Process
Controlled process is considered fast if its period of oscillation is less than three times that of positioned valve. If the period of oscillation is three times or more that of positioned valve, then the process is slow process.

Common Terms used in Control Valve

8. Cavitation
The high flow velocity at the vena contracta of the valve is reached by obtaining its energy from the pressure energy of the stream. This causes localized pressure reduction, if it drops below the fluids vapour pressure, results in temporary vaporization. Downstream of the vena contracta the pressure recovers in the valve causes the temporary voids to collapse. This procedure is called CAVITATION. Cavitation generate extremely high pressure shock waves in the non-compressible stream. When these waves strike the solid metal surface of the valve or downstream piping, it may cause damage to valve internals and piping. Cavitation is usually coupled with vibration and a sound like rock fragments or gravel flowing through the valve.

7. Flashing
Flashing begins in the same manner as Cavitation. In case of Flashing pressure downstream remains at or below vapour pressure. This causes vapour to stay in vapour phase as fluid leaves the valve and enters the downstream piping. The specific volume increases as liquid changes to vapour, which in turn causes an increase in the fluid velocity. If enough vapour is formed, the resulting high valve outlet or pipe velocities can erode metal.

Control Valve
Actuator

Bonnet

Positioner Body

Different Components of Control Valves

Valve Body

Trim

Trim consists of internal parts contained within the body and wetted by the process fluid The main components are Plug, Stem, Seat Rings, cage, seat retainers, spacers, guide bushing etc. Trim parts create flow restriction or throttling action and is responsible for most of the pressure loss dissipated in the valve Trim design serves to determine the inherent flow characteristics of the valve

Quiz No. 1
Define Flow Coefficient Cv of a valve.

Different types of Valves

Linear Valves 1) Globe Valves 2) Gate Valves 3) Saunders Diaphragm Valves Rotary Valves 1) Ball Valves 2) Butterfly Valves 3) Plug Valves

Globe Valves
Single Ported Single Ported Single Ported Double with Cage Split Body Ported, topCharacteriGuided bottom (C) zed Plug guided or (B) skirt guided (A) plug (D) Angle (E) Y- Type (F) Three Way (G) Eccentric Plug, Rotary Globe (H)

Type

Sizes

Typically NPSTypically NPSTypically NPSTypically NPSTypically NPSTypically NPSTypically NPSTypically NPS to 16 (DN to 16 (DN to 10 (DN to 16 (DN to 16 (DN 1 to 16 (DN to 6 (DN 1 to 12 (DN 15 to DN 400)15 to DN 400)15 to DN 250) 15 to DN 400)15 to DN 400)25 to DN 400) 15 to DN 150)25 to DN 300) : Available : Available : Available : Available upto NPS 48 upto NPS 48 upto NPS 48 upto NPS 24 (DN 1200) (DN 1200) (DN 1200) (DN 600)

Design Pr. Typically all ratings are available from ANSI Class 150 (PN 20) to Class 2500 (PN 420) with special designs upto Rating Class 4500 ; Types C & H are limited to ANSI Class 600 (PN 100) ; DN = Nominal Diameter in mm, PN = Pressure, Nominal in Bar Maximum Upto maximum allowed by body pressure rating depending on limitations of actuator size and trim design and Pressure materials Drop Design Depends on material properties. Generally from -20 to 1200 Deg F (-29 to 538 Deg C). Cryogenic design for Temperat-ure temperature down to 423 Deg F )-253 Deg C). Special Valves have been designed for operation upto 1600 Deg F (871 Deg C)

Globe Valves
Single Ported Single Ported Single Ported Double with Cage Split Body Ported, topCharacteriGuided bottom (C) zed Plug guided or (B) skirt guided (A) plug (D) Angle (E) Y- Type (F) Three Way (G) Eccentric Plug, Rotary Globe (H)

Type

Material Of Body and Bonnet Materials : Most cast and forged grades of carbon steel, low alloy steel, stainless steel, alloy Construct-ion 20, duplex stainless steel, nickel and nickel alloy, bronze, titanium and zirconium. Fluropolymer lining also available for corrosion protection. Trim Materials : Generally available in stainless steel, nickel, nickel alloys, bronze, titanium and zirconium. Hard facing is available for erosive application. Seal and soft seat materials : FEB, PFA, PTFE, PCTFE, ETFE, EPT / EPDM, Fluoroelastomers, Nitrile, Polyethylene, Polyurethane, UHMWPE, compressed graphite, and soft metals. Leakage Metal seats in double ported design are Class II, while in single seated design they can meet Class IV and Class V. Soft seats in double ported designs can meet ANSI Class IV and V, while in single seated globe valves they can give Class VI performance

Character- Available in all type of characteristics istics Rangebility Based on ISA-75.11 or IEC 60534-2-4, it seldom exceeds 30 : 1. Special design can achieve 50 : 1 or higher by increasing precision of control at small valve openings. Capacity Cv = 10 d2 to 15 d2with single ported design closer to the bottom of the range and with double ported and eccentric disc designs closer to the top of the range

Globe Valves
Advantages :
1. Simplicity of pneumatic actuator designs 2. Availability of a wide range of valve characteristics 3. Relatively low likelihood of cavitation and noise 4. Availability of wide variety of specialized designs for corrosive, abrasive and high temperature or high pressure application 5. Relatively small amount of dead band and hysteresis

Globe Valves
Disadvantages :
1. Higher cost per unit of Cv 2. Greater weight and dimensional envelope relative to their flow capacity

Globe Valves
Body Forms :
1. Double Ported Valves 2. Single Seated Valves 3. Cage Valves 4. Pressure Balance Valves 5. Split Body Valves 6. Angle Valves 7. Y Type Valves 8. Eccentric Plug Rotary Globe Type 9. Three Way Valves

Globe Valves
1. Double Ported Valves
First Globe Valve developed during the early 20th century Larger and heavier than single seated valves Shut off is poor because it is not practical to have both plugs in tight contact with seats at the same time These are semi balanced i.e. the hydrostatic forces acting on the upper plug partially cancels out the forces acting on the lower plug Less actuator force required, hence smaller actuator can be used.

Globe Valves
2. Single Seated Valves
Most widely used Globe Valve Body Pattern Available in wide variety configuration, including special purpose trims Have good seating shut off capability Less subject to vibration due to reduced plug mass Easy to maintain

Globe Valves
Single Seated and Double Seated Valves has three general types of seat constructions : 1) Floating Seat Ring Seat ring sits in machined bore in the body with a gasket to seal the joint between the body and seat ring. It must be retained in the body by cage or seat retainer to maintain gasket tightness and concentricity with the plug. This can be replaced 2) Screwed Seat Ring Seat ring is threaded with a special tool ; a gasket may or may not be required. A separate seat retainer is not required. This can be replaced.

3) Integral Seat Ring The seating surface is machined directly into the body; This cannot be replaced.

Globe Valves
Single Seated and Double Ported valves has four different types of valve plug guides: 1) Post Guided Provide more stream lined flow less subject to fouling in dirty service 2) Top and Bottom Guided Has similar limitation as Double Seated Valves 3) Stem Guided Provide more stream lined flow less subject to fouling in dirty service Minimizes stagnant fluid cavities Better when dealing with fluids containing solids, sticky or viscous fluids, or highly corrosive fluids.
Top & Bottom Guided

Post Guided

4) Cage Guided Discussed under Cage Valves

Stem Guided

Globe Valves
3. Cage Valves
It has rugged design With proper selection of trim type and materials, these valve provide relatively trouble free service for extended time period. These are of two basic design configurations : 1) One type uses cage solely as a seat retainer to clamp a floating seat ring into the valve body. This design is usually stem guided or post guided. The valve plug is characterized. Cage does not guide or control flow. 2) Second type uses cage to guide plug and cage opening are shaped to provide the desired flow characteristic. These are called Cage Guided Valves.

Globe Valves
4. Pressure Balanced Valves
Provide better control for high pressure drops applications Reduces the magnitude of unbalanced plug forces Reduces the Actuator Size used It degrades the valve shut-off capability to some degree In these valves there is provision for a pressure path from the upstream pressure side of the plug to the area above the plug, allowing upstream pressure on the upper plug area, hence balancing the plug.

Globe Valves
5. Split Body Type Valve Designed for hard to handle services involving slurries, gummy liquid
corrosive service.

Seat ring is clamped between the body halves, and the body is easily disassembled for maintenance. Available with limited trim design. Body flange is more prone for leakage.

Globe Valves
6. Angle Valves
Used in a flow to close direction for high pressure drop services Tungsten carbide or ceramic can be selected to resist erosion due to higher trim velocities. Venturi style outlet has high pressure recovery and low vena contracta pressures, which makes the trim and down stream piping highly susceptible to cavitation on liquid service, even with moderate pressure drops. In order to avoid damage of piping, these valves are installed directly on vessels or with larger downstream pipe.

Globe Valves
7. Y-Type Valves
These are used where good drainage of body passage is required or high flow capacity is required, such as in controlling molten metals or polymers, cryogenic fluids and liquid slurries. These valves can be installed in horizontal, vertical or angled piping.

Globe Valves
8. Eccentric Plug Rotary Globe Valve
Its design and performance combine features of conventional rotary valves with conventional globe valves. Compared to most rotary valves, the valves has the advantage of lower torque requirement The plug design uses the offset center to obtain contact at closure without rubbing on the seat, like ball valves It is capable of substantial seat contact loading for tight shut off approaching that of conventional globe valves. Flow characteristics approaches linear Flow capacity is between double ported globe and a high performance, double offset butterfly valve. Less likely to cavitate, as pressure recovery in the body is moderate.

Globe Valves
9. Three Way Valves
Specialized double seated globe valve Available in two types : One is for mixing and other for diverting service These valves are not used for high pressure drop service. Has similar limitations as of double seated valves

Globe Valves
Valve Connections :
Flanged End Screwed End Welded End

Globe Valves
Valve Material of Construction:
Piping specification defines the Material of Construction

Ball Valves
Conventional (A) Type Sizes & Design Pressure to 42 (12 to 1180 mm) in ANSI Class 150 to 12 (300 mm) in ANSI Class 2500 1 to 24 (25 to 600 mm) to 14 ( 6 to 350 mm), Up to in ANSI Class 150; to 16 ANSI Class 2500 (400 mm) in ANSI Class 300; to 12 (300 mm) in ANSI Class 600 From -50 to 300 Deg F (- From 425 Deg F to 1800 45 to 150 Deg C); Deg F ( -255 to 980 Deg C) special units available from cryogenic to 1000 Deg F (540 Deg C) Characterized (D) Cage (C)

Design Temp.Varies with size and material, Rating typically from -250 to 600 Deg F (-155 to 315 Deg C) with special designs available from -300 to 1800 Deg F (-185 to 1020 Deg C)

Rangability Generally claimed to be about 50 : 1 CharacteristicBetween Equal Percentage and Linear s Capacity Std. Ball : Cv = 30 d2 to Cv =Cv = 24 d2 to Cv = 30 d2 45 d2 Full Bore Ball : Cv = 35 d2 to Cv = 100 d2 Cv = 20 d2

Globe Valves
Conventional (A) Type Material Of Body : Cast or bar stock brass or bronze, carbon steel , stainless steel, ductile iron, aluminium, monel titanium, Construct-ion Hastelloy C, plastics, glass; also hafnium free sirconium ( for nuclear applications) and ceramic for abrasives. Ball : forged naval bronze, carbon steel ( also plated), stainless steel, plastics, glass, ceramics, alloy 20, Monel, Hastelloy C, aluminum, titanium. Seats : Teflon, Kel-F (both tetrafluoroethylene), Delrin, buna-N, neoprene, perbunan, Hypalon, natural rubber, graphite. Leakage Metal seats : ANSI IV to VI Composition seats : ANSI V or better Charecterized (B) Cage (C)

Ball Valves
Advantages :
1. Lower Cost 2. Lower weight 3. Higher flow capacity (two to three times that of globe valve) 4. Tight shut off 5. Fire Safe Design 6. Low stem Leakage (make it easier to meet governmental regulator requirements from OSHA and EPA in the US and the Pressure Equipment directive (PED) in the EEC.

Ball Valves
Disadvantages :
1. Valves high capacity results in either using oversized valves or installing small valves in large pipes. This means a substantial waste of pumping energy caused by the reducer pressure drop. These valves has the characteristic of a high pressure recovery results in low vena contracta pressure. This in turn increases probability of cavitation and noise. In operating rotary valves, the linear movement of cylinder or spring / diaphragm type actuators must be converted by linkages, which introduces hysteresis and dead band. A non linear relationship exists between actuator movement and the resulting rotation. These considerations make the use of positioners essential, which on fast processes can lower the quality of control. The torque charecteristics of these vavles are also highly non linear and because of the high break torque requirement, the actuator is usually oversized for the operation in the throttling range

2.

3. 4.

5.

Ball Valves
Types of Ball Valves
1. Conventional Ball Valves 2. Characterized Ball Valves 3. Cage Type Ball Valves

Ball Valves
1. Conventional Ball Valves
Available as Full Bore or Reduced Bore and Trunnion mounted or floating Requires quarter turn (90o) to fully uncover or fully cover an opening Valve design is standard, they can be used with or with out actuator, hence third party actuator can be used. Available is configurations such as two-way, three-way or split body. Available with metal seat, soft seat or combination of metal & soft seat (Fire safe design) Flow charectaristics of the ball valve approximate those of an equal percentage plug

Ball Valves
2. Characterized Ball Valves
Available as V-Notched, U-Notched, parabolic design The ball is modified so that only a portion of it is used. The edge of partial ball can be notched or contoured or shaped to obtain the desired valve characteristics Limitation is, mechanically the notched partial ball can bend under pressure and thus introducing movement into the shaft seals or distort the shaft. The characteristics of the notch and parabolic ball valve is near to equal percentage. If the characteristics were evaluated using compressible fluids at critical velocities, these curves would be flatter, closer to linear.

Ball Valves
3. Ball and Cage Valves
Under this design the ball is positioned by cage, in relation to a seat ring and discharge port. The valve consists of a venturi ported body, two seat rings, a ball that causes closure, a cage that positions the ball, and a stem that positions the cage. Seat rings are installed in both inlet and discharge, but only the discharge ring is active. The body can be reversed for utilization of the spare ring. The flow coefficients (Cv) are consistently high. Rangability 50 : 1. Tight shut off occurs over a long operating life due to the continual rotation of the ball at each operation which offer a new seating surface each time it is closed. Low opening force is required, hence the size of actuator required is relatively small.

Ball Valves
3. Ball and Cage Valves
Minimizes cavitation effects because flow tends to follow the curve of the ball, thus reducing turbulence. The cavitation tends to occur in the venturi passage, not at the seat, allowing use of hardened or replaceable throats. The expanding venturi discharge assists in handling flashing liquids.

Butterfly Valves
General Purpose, aligned shaft Type Sizes 2 to 48 ( 51 mm to 1.22 m) are typical, but units 4 to 16 ( 0.1 to 0.4 m) are common, but units are available have been made in sizes from 0.75 to 200 (19mm from 2 to 80 ( 50mm to 2 m) to 5 m) Most arfe available through ANSI Class 300 ratings For installation purposes most are available through ANSI and for up to 200 psid ( 1.4 MPa) pressure drop. 600 ratings and for up to 720 psid ( 5 MPa) pressure drop Special units have been designed for up to 6000 PSIG design pressure High performance, offset shaft

Design Pressure Rating

Design Temp.-450 to 1000 Deg F ( -268 to 538 Deg C). Special -320 to 450 Deg F ( -196 to 232 Deg C) for Teflon seated Rating refractory lined units have been made for up to valves; 1200 Deg F (649 Deg C) for metal seated ones. 2200 Deg F ( 1204 Deg C) Special units are available up to 1700 Deg F (927 Deg C) Body / Disc Iron, ductile iron, carbon or alloy steels, stainless Steel, 316 SS, alloy steel, Durimet 20, aluminum bronze, Material steel (302 316), aluminum bronse, Alloy 20, Alloy 20, Monel, Hastelloy C, titanium, tungstem titanium Monel, Hastelloy C, titanium, chrome plating, nickel carbide (TTC) coating plating, kynar, Nordel, Viton, EPDM, Buna-N, neoprene elastomer lining, TFE encapsulation Seat Material TFE, Kel-F, EPT, Polyethylene, PTFE with titanium, Inconel, or 316 stainless steel or other metals.

Globe Valves
General Purpose, aligned shaft Type CharacteristicLinear to quick opening s Rangeability Generally claimed as 50 : 1 Leakage Capacity Unlined, 2 to 5%, lined, ANSI V With 60 Deg rotation, Cv = (17 to 20) d2. Typical for throttling with 75o rotation, Cv = ( 25 to 30) d2; with 90o rotation , Cv = ( 35 to 40) d2 Metal seat, ANSI IV; soft (toggle) seat, ANSI VI Cv = (20 to 25) d2 High Performance, offset (eccentric) shaft

Special feature

Reduced torque disc designs, fire tested seals, reduced noise disc, special disc seal designs

Butterfly Valves
Advantages :
1. Lower Cost 2. Lower weight 3. Higher flow capacity (two to three times that of globe valve) 4. Tight shut off 5. Fire Safe Design 6. Low stem Leakage (make it easier to meet governmental regulator requirements from OSHA and EPA in the US and the Pressure Equipment directive (PED) in the EEC.

Butterfly Valves
Conventional ButterFly Valve :
One of the oldest type of valves Dictionary defines the butterfly valve as a Damper or throttle valve in a pipe consisting of a disc turning on a diametral axis Butterfly valve operation involves only rotating the vane, disc, louver, or flapper by means of the shaft to which it is fastened to either manually or using actuator. Butterfly valve are available in swing through design Swing through designs have a symmetrical disc and shaft design with a certain clearance required between disc and body. The body is usually the solid ring type, which is mounted between pipe flanges. It can be either the wafer type or the single flange lug pattern, where flange bolting goes thru body.

Butterfly Valves
Conventional ButterFly Valve :
The thickness of the disc and hub along with the diameter of the shaft is a function of the maximum pressure drop and torque required. Swing thru designs are available with a variety of disc shapes that serves to reduce the required torque and to increase throttling angle range. Swing thru designs are limited to a maximum throttling of angle about 70 Deg open for the standard pattern and 60 Deg for heavy pattern due to their larger diameter shafts.

Butterfly Valves
High Performance ButterFly Valve :

The features include tight shut off, reduced operating torque, excellent throttling capabilities, able to operate with relatively high pressure drops, compact size, reduced weight and lower cost. There are many designs all have characteristics of separable seat ring contained in the body and an eccentric cammed disc. The camming action enables the disc to back out of and into the seat before and after the disc rotation when throttling. This is accomplished by having the shaft offset from both the centerlines of the disc and the valve body. Tight shutoff is accomplished by two methods, one by providing valve with an elestomer or plastic liner, in this configuration the disc is also encapsulated in some cases and the other is with cammed disc and a separate seal ring clamped into the body.

Butterfly Valves
High Performance ButterFly Valve :
These valves are available with soft seal achieving ANSI Class VI shut off and for high temp application metal seat achieving ANSI Class IV. Some achieve ANSI Class V also. These are available in fire safe design i.e. soft seat backed up with metal seat. Various disc designs are available which improves the noise reduction. Cambered and fishtail type disc generated lesser noise than convention swing thru type disc. Fluted type disc reduces the noise by another 10 dB on a weighted scale.

Plug Valves
Type Sizes Design Pressure Rating V-ported, three way, Four Way, Five way, Fire Sealed to 36 (12.5 to 0.96m) Typically from ANSI Class 125 to ANSI Class 300 ratings and up to 720 psig ( 5 MPa) pressure, with special units available for ANSI Class 2500. The retractable seat design is suited for 10,000 psig (69 MPa) service

Design Temp.Typically from -100 to 400 Deg F ( - 73 to 204 Deg C) with special units available from 250 to 600 Deg F ( -157 to Rating 315 Deg C) Material of Iron, forged and alloy steel, chrome plating, 302 thrugh 316 SS, Alloy 20, Ni- resist, Monel, nickel, Hastelloy B Construction and C, and zirconium, plug rubber or plastic, including PTFE linings CharacteristicEqual Percentage, Modified parabolic, Modified linear s Capacity Cv = (25 to 35) d2

Rangability Generally 20 : 1 Leakage Metal seats ANSI Class IV, composition seats ANSI Class V

Plug Valves
1. Lower Cost 2. Lower weight 3. Higher flow capacity (two to three times that of globe valve), high flow at low pressure drop 4. Tight shut off 5. Fire Safe Design 6. Suited for corrosive, viscous, dirty fibrous or slurry services 7. Not recommended for applications where cavitation or flashing is expected 8. Low stem Leakage (make it easier to meet governmental regulator requirements from OSHA and EPA in the US and the Pressure Equipment directive (PED) in the EEC. 9. The design using characterized or eccentric rotating plugs provide good control performance and a self cleaning flow pattern, which also reduces noise and cavitation 10. These provide superior stem sealing capability, plug valves are also suited for such corrosive applications as chlorine, phosgene, hydrofluoric acid, and hydrochloric acid. These are widely used on lethal and toxic services and can be made fire safe by the use of grafoil packing and meet the external leakage requirement limits of API 607

Plug Valves
11. These valves afford quick opening or closing with tight, leak proof closures under conditions ranging from vacuum to pressures as high as 10,000 psig (69 MPa). 12. Plug valves are also designed with various characterized and Y-ported or diamond design, can be used for throttling, while others, like the multiport, are used for diverting and bypass applications. 13. Plug valves are used on gas, liquid and non abrasive slurry services.

14. Lubricated plug valves can also be used for abrasive slurries, and eccentric plugs are also used on application involving sticky fluids. 15. Plug valves are also used for applications requiring the contamination free handling of foods and pharmaceuticals. 16. Suitable for low flow control, Flow diversion, High or low temperature applications, vibration free operation, Throttling control, only with eccentric and V ported characterized designs. 17. The conventional plug valves are generally undesirable for the following types of applications : - Flow modulation or continuous, exact flow throttling - Maintenance free operation (Occasional lubrication is usually required and plugs may wear)

Plug Valves

Saunders Diaphragm Valves

Type Application Sizes Weir, full-bore, straight through, dual - range Slurries, corrosive fluids at low pressure drops Standard units from to 12 (12 to 300 mm); special units upto 20 ( 500mm)

Max In sizes up to 4 (100mm), 150 psig (10.3 bar); 6 (150mm), 125 psig (8.6 bar), 8 ( 200mm), 100 psig (6.9 bar) Operating and 10 or 12 (250 or 300mm), 65 psig ( 4.5 bar) Pressure Vacuum Limits Mechanical damage can occur when opening valve against process vacuum

Temperature With most elastomer diaphragms from 10 to 15 Deg F (-12 to 65 Deg C); with PTFE diaphragm from -30 to 350 Limits Deg F ( - 34 to 175 Deg C) Material of Body materials : Iron, ductile iron, steel, 302 to 316 SS, Alloy 20, bronze, Monel, Hastelloy C, aluminum, Construction titanium, graphite, plastic such as PTFE lining or solid plastics Diaphragm materials : Teflon, Buna N, neoprene, hypalon CharacteristicLinear and quick opening s Capacity Cv = 20 d2

Rangability About 10 : 1 Leakage ANSI Class IV and V

Saunders Diaphragm Valves

Advantages : 1. Lower Cost 2. Tight shut off 3. Suitability for corrosive, dirty, viscous or slurry services

Dis - Advantages : 1. Limited in their temperature (high and low) and pressure (high) ratings 2. Not suited for cavitating or flashing services

Conventional Saunders Diaphragm Valves

It utilises both diaphragm and weir for controlling the flow

Straight Through Saunders Diaphragm Valves

It has longer stroke length Increased flexure requirement tends to shorten the life of the diaphragm Straight through design has smooth, self draining, straight through flow pattern makes it applicable to handle materials, such as slurry. Flow characteristic of the straight through design is more nearly linear than those of the conventional Saunders valves

Full Bore Saunders Diaphragm Valves

The body of a full bore of a full bore Saunders valve is modified to provide a special shape to the weir. The opening of the internal flow path is fully rounded at all points, permitting ball brush cleaning. This an important feature in the food industry, where a smooth, easy to clean interior surface is required.

Dual Range Design Saunders Diaphragm Valves

It is operated using two compressing members, hence improving the control capability The type of shape during the valve opening helps prevent clogging, it also keeps abrasion at a minimum

Sliding Gate Valves

Type Sizes Design Pressure Vacuum Limits Design Cryogenic to 500 Deg F ( 260 Deg C) Temperature -20 to 1125 Deg F (-29 to 607 Deg C) Knife gate On / Off 2 to 120 ( 50mm to 3 m) V-Insert Throttling to 24 (12 to 600mm) Plate and Disc (Multi orifice) Throttling to 6 ( 12 to 150mm) Upto ANSI Class 300 Positioned disc Throttling 1 to 2 ( 25 to 50mm) Upto 10,000 psig (69 MPa)

Up to ANSI Class 150; higher with wedge within wedge design

Material of Ductile iron, cast iron, carbon steel, 304, 316, 317 Body : Ductile iron, bronze, Construction stainless steel, Alloy 20, Hastelloy. For V-Insert, seatingcarbon steel, stainless can be metal to metal, nylon or RTFE steel, aluminum, Monel Trim : SS, which can be chrome plated for hardness or Teflon coated for corrossion resistance; Monel and Hastolloy are also available

Sliding Gate Valves

Type Charecteristic s Capacity Cv = 45 d2 Knife gate V-Insert Parabolic Cv = 30 d2 Plate and Disc (Multi orifice) Linear Cv = 6 - 10 d2 Positioned disc Quick Opening

Leakages ANSI Class I or II with metal seat; better with soft seat ANSI Class IV or lining

Knife Edge Gate Valves

Relatively in expensive Have high capacity Suitable for slurry and dirty services They have poor control characteristics Do not provide tight shut off Not suitable for corrosive services

V-Insert Type Gate Valves

Better control characteristics than knife edge gate valve.

Positioned Sliding Disc Gate Valves

Ideal for high pressure (upto 10,000 PSIG), Can be used for cavitating, abrasive, or erosive services Relatively expansive Not suitable for sludge, slurry, viscous, or fibrous services

Quiz No. 2
What are the different types of Control Valves ?

Different types of Actuators

1) Linear 1a) Spring And Diaphragm 1b) Piston 2) Rotary 2a) Cylinder with Scotch yoke 2b) Cylinder with rack and pinion 3) Electric Actuators

Different types of Actuators

1a) Spring And Diaphragm
These are pneumatically operated, uses air supply from controller, positioner or other sources. These are of various types : direct acting (increasing air pressure pushes down diaphragm and extends actuator stem) ; reverse acting (increasing air pressure pushes up diaphragm and retracts actuator stem) ; reversible (actuators that can be assembled for either direct or reverse action) ; direct acting unit for rotary valves (increasing air pressure pushes down on diaphragm, which may either open or close the valve, depending on orientation of the actuator lever on the valve shaft) Net output thrust is the difference between diaphragm force and opposing spring force Molded diaphragms provide linear performance and increased travels Output thrust required and supply air pressure available dictate size Disphragm actuators are simple, dependable and econoical.

Different types of Actuators

1a) Spring And Diaphragm

Different types of Actuators

1b) Piston Actuator
Piston actuators are pneumatically operated using high pressure plant air to 150 psig, it eliminates the need for supply pressure regulator. Piston actuators are double acting type to give maximum force in both direction, or spring return to provide fail open or fail closed operation Various accessories can be incororated to position a double acting piston in the event of supply pressure failure. These include pneumatic trip valves and lock up systems. Also available are hydraulic snubbers, handwheels, and units without yoke, which can be used to operate butterfly valves, louvers, and similar industrial equipment.

Different types of Actuators

2a) Cylinder with Scotch yoke

Different types of Actuators

2a) Cylinder with Rack and Pinion Type

Different types of Actuators

3) Electric Actuators
Electrical Actuators uses either reversible motor, servomotor drive or stepping motors. Reversible motor can operate both linear or rotary valves Servo motor drives can position valves in rosponse to feedback signals from linear or rotary encoders Stepping Motors are well suited for direct digital control and pulse feedback can be provided for accurate closed loop positioning.

Different types of Accessories used with Control Valves

1) Positioners 2) I/P (Electropneumatic) Transducers 3) Booster Relays 4) Quick Exhaust Relays 5) Relays to lock up Valve position 6) Air Sets 7) Limit Switches 8) Solenoid Valves 9) Hand Wheels 10) Limit Stop

Different types of Accessories used with Control Valves

1) Positioners
These are high gain plain proportional only controller. It measures valve stem position (to within 0.1 mm), compares that measurement to its set point ( controller output signal), and if there is diff. corrects it. These are available in pneumatic and electronic (intelligent). Purpose of positioner is to guarantee that, the valve does ,in fact, move to the position where the controller wants it to be. Advantages of positioner are : corrects any variation due to packing friction due to dirt, corrosion, lack of lubrication, variation to dynamic forces of the process, sloppy linkages (dead band), non linearity of actuator. Split ranging the controller signal Increases loop gain and hence loop response in slow process. Eliminates dead band and hysteresis

Different types of Accessories used with Control Valves

1) Positioners
Disadvantages of positioner are, In case of fast loop, positioner are likely to degrade loop response, contribute to proportional offsets, and cause limit cycling ( fast flow, Liquid pressure, small volume gas pressure).

Types of positioners Force Balance Positioner Motion Balance Positioner Electrohydraulic Positioners Digital to Pneumatic Positioners

Different types of Accessories used with Control Valves

2. I/P (Elecropneumatic) Transducer
It converts electrical signal ( 4 20mA) from controller to pneumatic signal (3 15 psig or 0.2 to 1 Barg). The most common application is the Interface between and electronic controller.

Most of the transducer design is Motion Balance Type.

3. Booster Relay
It amplifies pneumatic signals in volume (capacity) or in pressure, or both. Large control valves and large actuators may require flow or pressure boosters installed between the positioner and the actuator to achieve the required speed.

Different types of Accessories used with Control Valves

4. Quick Exhaust Relays
Also called quick exhaust dump valve, is a pilot valve that opens a high capacity vent when the input pressure drops below a set pressure. This is used when it is needed to quickly open a valve that vents a vessel Or system during a shut-down.

5. Lock Up Valve Position Relay

It holds up the valve in its last position if the air supply is lost.

Different types of Accessories used with Control Valves

6. Air Set
It consists of air regulator with filter and drip pot. It is used to supply moisture free, oil free and particle free (equal or above 5 micron) air supply to the positioner other instruments. It is often purchased with the valve, mounted and tubed. Regulator must have the pressure range to cover the spring range of the actuator, and it should have built in overpressure vent to protect the Actuator. A gauge is valuable to aid in setting the output pressure and for discovering a failed or plugged supply.

Different types of Accessories used with Control Valves

7. Limit switches
Used to indicate closed or open position of the valve. These are available in two types sealed magnetically actuated or Proximity switches and mechanically actuated switch. When specifying, specify the required contact ratings, the contact Configurations (SPDT, DPDT, and so on), and the type of housing.

8. Solenoid Valves
These are used a) to operate on / off pneumatic actuators b) to Interrupt the action of modulating valves. Solenoid valves are usually used as pilot valve. Solenoid Valves are available as Three Way and Four Way. Solenoid valve Cv should be more than Cv of Positioner to avoid reduction in stroke speed.

Different types of Accessories used with Control Valves

9. Handwheel
Handwheels are used to provide manual control of the valve and to Override the actuator. These are available as Top Mounted and Side Mounted.

10. Limit Stop

Limit stop is used to limit valve stem motion to either ensure a minimum opening or limit a maximum opening.

Sizing of Control Valve

Sizing equation for control valve is based on Bernoullis theorem for the conservation of energy and the continuity Equation for the conservation of mass. The generally accepted valve capacity parameter called the valve coefficient is : Cv = Q x sqrt (G / Press. Drop) The equation is valid for turbulent and non choked (low pressure drop) liquid flows. The above equation alone turned out to be inaccurate. This was corrected by adding various factors like Pressure Recovery Factor FL, Pressure Differential Factor Xt , Expansion factor Y, Pipe Geometry FP, Reynolds No. Factor FR, Liquid Pressure Recovery Factor FF etc. Using above factors, various formulas were developed for Non choked, tubulent flow in liquid, Non choked vapour and gas, Choked Flow due to cavitation and flashing Liquids, Choked flow due to sonic velocity in gases and vapours, nonturbulent (viscous) flow liquids.

Sizing of Control Valve

STEPS TO SIZE A VALVE : Determine minimum and maximum Cv requirements for the valve, considering not only normal but also start-up and emergency conditions. Decide what type of valve will be used.

From the manufacturer valve chart select a valve. Select a valve with Cv within 10% to 80% of stroke range. The size of valve selected will usually be turned out to be smaller than the line size. Never select valve less than half the pipe size. It is ideal to select valve with one size smaller and if the required Cv is still smaller then select reduced trim design.

Sizing of Control Valve

Check the gain across applicable flow rate Gain = Change in Flow / Change in valve stroke or travel e.g. Min / Nor / Max Flow = x1 / x2 / x3 Cvmin / Cvnor / Cvmax / = Cv1, Cv2, Cv3 Corresponding stroke % = S1%, S2%, S3% Gain #1 = (x2 x1) / (S2 S1) = Y1 Gain #2 = (x3 x2) / (S3 S2) = Y2 The difference between the Gains ( Y2 Y1) should be less than 50% of higher value between Y1 and Y2. Also note that the gain should never be less than 0.5.

Selection of Valve Characteristics

Selection of right characteristics is important because it is part of control loop, and the loop will be Stable only if the products of all its gain components (the gains of the process, sensor, controller and The valve gains) is constant. Usually the controller is tuned so that this gain product is 0.5, in order to give quarter amplitude Damping. If the gain of loop do not vary with load, but is constant, the desirable choice is to use a constant gain Valve (i.e. linear valve) If the gain of the loop components (such as process) decreases with load (flow thru the valve), the Proper choice is to use increasing gain valve (i.e. equal percentage valve).

Selection of Valve Characteristics

There are different engineer who had developed different rules of thumb to be used in selecting valve Characteristics, One of the engineers Lytles recommendations are as follows : LIQUID LEVEL SYSTEM Constant dP Linear

Decreasing dP with increasing load, dP at maximum load is greater than Linear 20% of minimum load dP Decreasing dP with increasing load, dP at maximum load is less than 20% of minimum load dP Increasing dP with increasing load, dP at maximum load is less than 200% of minimum load dP Equal Percentage

Linear

Increasing dP with increasing load, dP at maximum load is greater than Quick Opening 200% of minimum load dP

Selection of Valve Characteristics

Pressure Control System Liquid Process Equal Percentage

Gas Process, small volume, less than 10 ft of pipe between control valve Equal Percentage and load valve Gas Process, large volume (process has a receiver, distribution system, Linear or transmission line exceeding 100 ft of nominal pipe volume, decreasing dP with increasing load, dP at maximum load greater than 20% of minimum load dP Gas process, large volume, decreasing dP with increasing load dP at maximum load less than 20% of minimum load dP Equal Percentage

Selection of Valve Characteristics

Flow Control System Flow Measurement Signal to Controller Location of Control Valve Relation to Measuring Element Wide Range of Small Range of Flow Flow Setpoint but Large dP Change at Valve with Increasing Load Linear Equal Percentage

Proportional to Q

In series

Proportional to Q

In bypass

Linear

Equal Percentage

Proportional to Q2

In series

Linear

Equal Percentage

Proportional to Q2

In bypass

Equal Percentage

Equal Percentage

Selection of Valve Characteristics

Temperature Control System It is recommended to have Equal Percentage Control Valve.

Leakage Classes in Control Valve

As per ANSI FCI 70-2 ( earlier ANSI B 16.104), valves are categorized according to their allowable Leakage into six classes. These leakage limits are applicable to unused valves only, Class I Class II Class III Class IV Class V Class VI Valve are neither tested nor guaranteed for leakage Valves are rated to have less than 0.5% of their capacity Valves are allowed up to 0.1% of their capacity Valves must not leak more than 0.01% of their capacity Valves are specified to have a leakage of 5 x 10-4 ml/min water flow per inch of seat diameter, per 1 psi (0.0685 bar) differential pressure This is for soft seated valves, and leakage is expressed as volumetric air flow at rated pressure drop of 50 psi (3.45 bar)

Standards :
IEC 60534, Part 1, 2, 3, 4, 5, Describes Terminology, Sizing, Test Procedures, Dimensions, Inspection and routine testing and Marking Control Valve Sizing Equations Control Valve Capacity Test

ISA S 75.01, 2000 ISA S 75.02, 1996

Quiz No. 3
What are the different types of Accessories used with Control Valves ?

Thank You