FUNDAMENTALS OF CONTROL VALVES

CONTROL VALVE
I

A CONTROL VALVE IS A FINAL CONTROL ELEMENT AND A POWER OPERATED DEVICE WHICH MODIFIES THE FLOW RATE IN A PROCESS CONTROL SYSTEM.

ROLE OF A CONTROL VALVE

It is used for I The correct distri utio! "!d co!tro# of I F#o$i!% f#uid or %"ses I Reductio! of Pressure I As " &"ri" #e orifice I As " thrott#i!% or 'odu#"ti!% e(ui)'e!t

CONTROL VALVE PARTS

*. +ODY ,. VALVE -. ACT.ATOR

BODY
I

The od/ is the )ressure c"rr/i!% )"rt "!d it 'eets "## their "))#ic" #e )ressure0 te')er"ture "!d corrosio! re(uire'e!ts.

THE +ODY PROVIDES I THE PIPIN1 CONNECTIN1 ENDS I FL.ID FLOW PASSA1E WAY0 AND S.PPORT THE SEATIN1 S.RFACE I THE VALVE CLOS.RE MEM+ER

BODY- INTERNAL PARTS

GLAND PACKING

BODY FLANGE STEM WITH PLUG

INLET

OUTLET SEAT

TRIM
I

The tri' of the &"#&e co!sists of "## the )"rts $hich $i## e $etted other th"! the od/ "!d the o!!et Tri' is the he"rt of the &"#&e $ith " )ri'"r/ fu!ctio! to )ro)ortio! the &"#&e orifice i! such " '"!!er th"t " )rescri ed re#"tio!shi) e2ists et$ee! f#o$ c")"cit/ "!d &"#&e )#u% #ift The seco!d"r/ fu!ctio! '"/ e shut off ti%ht#/.

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, antern !ing, and Packing !etaining !ing" Secondar# trim parts are stem to plug attachments , seat retaining ring, seat to bod# seals and spacers"

YOKE
.
I

A STR.CT.RE +Y WHICH THE DIAPHRA1M ASSEM+LY IS S.PPORTED RI1IDLY ON THE +ONNET ASSEM+LY

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

ACTUATOR

ACTUATOR
I

UTILISES AIR PRESSURE 3 ELECTRIC POWER . HYDRAULIC PRESSURE TO ACT ON A DIAPHRAGM / PISTON AND DEVELOP A FORCE TO MOVE THE ACTUATOR STEM

ACTUTATOR CLASSIFICATION

I I

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

ACTUATOR PARTS
VENT DIAPHRAGM PLATE DIAPHRAGM INPUT SIGNAL DIAPHRAGM CASINGS ACTUATOR SPRING ACTUATOR STEM SPRING SEAT YOKE INDICATOR GLAND STUDS SPRING ADJUSTER STEM CONNECTOR SCALE LOCK NUT BONET FLANGE

STUFFING BOX

GLOBE GLOBE GATE DIAPHRAGM PINCH OR CLAMP VALVE BALL ROTARY MOTION SEGMENTED BALL FULL BALL CYLIDRICAL PLUG TAPERED ECCENTRIC SPHERE ANGLE THREE-WAY LINEAR MOTION

BUTTER FLY

T / ) e s o f V " & #e s R o t " r / M o t io ! + " ## + u t t e r f #/ L i! e " r M o t io ! 1 #o e 1 #o e A ! % #e 1 " te T h re e W " / D i" ) h r " % ' P i! c h o r C #" ' ) P #u %

IT IS MOSTLY COMMONLY USED ONE. IT IS A VALVE WITH A LINEAR CLOSURE MEMBER MOST COMMON TYPE CONTROL VALVE CLASSIFIED AS SINGLE SEATED AND DOUBLE SEATED SINGLE SEATED CONFORMS TIGHT SHUT OFF. DOUBLE SEATED VALVE IS HAVING HIGH RESISTANCE TO VIBRATION AND ABRASION.

IT HAVE THE ADVANTAGE OF EASY TRIM REMOVAL . IT IS TOP ENTRY VALVE WITH UNBALANCED, SINGLE-SEATED TRIM. THE INNER VALVE PARTS CAN EASILY BE REMOVED AFTER REMOVING THE BONNET , BECAUSE ABSENCE OF INTERNAL THREADS.

ANGLE VALVES ARE SUITABLE FOR SLURRY FLUID , ADHESIVE FLUID AND HIGH VISCOSITY LIQUIDS.

SUITABLE FOR HIGH PRESSURE APPLICATION. HAS STRONG RESISTANCE TO VIBRATION AND WEAR

IT IS SIMPLY DESIGN EXTENSION OF DOUBLE SEATED GLOBE VALVE.

DIVIDES FLOW IN TWO DIRECTIONS

CONVERGES TWO STREAMS OF FLOW TO ONE

APPLICABLE WHERE STRAIGHT THROUGH FLOW PATH , TIGHT SHUT OFF AND EASE OF OPERATION ARE REQUIRED.

MOST SUITABLE FOR HANDLING SLURRIES AS IT MINIMISES THE TENDENCY OF THE FLUIDS TO EITHER SETTLE OR STAIN .

SUITABLE FOR HIGH FLOW CAPACITY..

B IT OFFERS THE ADVANTAGES OF SIMPLICITY, LOW COST, LIGHT WEIGHT,AND SPACE SAVING.
B

4 4 4

4 4

"

B VALVE IS SUITABLE FOR LOW PRESSURE DROP

APPLICATIONS

B ACTUATOR TORQUE REQUIRED IS LOWEST AS COMPARED TO OTHER VALVES " B IT HAS MAXIMUM FLOW CAPACITY " B INSTALLATION AND HANDLING IS EASY "

The m !" # mm $ "%&e ' ( ")(% *)+*e ,!e- ' ( # $"( + .! "he BUTTERFLY *)+*e. The "%&.#)+ )&&+.#)". $ ()$/e .! .$ !.0e! '( m 12 "h( ,/h 342 ( +)(/e(, ' ( + 5 ( m -e()"e &(e!!,(e!, ( $ ,$,!,)+ )&&+.#)". $! .$* +*.$/ +)(/e '+ 5! )" h./h !")".# &(e!!,(e! ,6," 5."h +.m."e&(e!!,(e -( &.

IT IS THE RELATION BETWEEN THE FLOW RATE THROUGH THE CONTROL VALVE AND PLUG TRAVEL , WHEN A CONSTANT PRESSURE DIFFERENTIAL IS MAINTAINED ACROSS THE VALVE THIS IS ACHIEVED BY VARYING THE FLUID FLOW AREA WITH RESPECT TO THE SHAPE OF THE PLUG.

THE DESIGN OF A CONTROL VALVE TRIM IS BASED ON THE FLOW CHARACTERISTICS . DIFFERENT CHARACTERISTICS WHICH ARE COMMONLY SELECTED TWO TYPES 7. TWO POSITION 8ON-OFF9CONTROL 1. THROTTLING CONTROL FLOW CHARACTERISTICS DECIDED BY SHAPE OF PLUG OR CAGE SLOTS.

THE PLUG IS THE MOVING COMPONENT OF THE VALVE WHICH THROTTLES FLOW BY POSITIONING ITSELF WITHIN THE SEAT ORFICE AND SHUTS OFF FLOW BY CONTACTING THE SEAT. THE PLUG IS MOVED AGAINST DYNAMIC FLUID FLOW

FORCES BY STEM FORCE TRANSMITTED FROM THE ACTUATOR. THE PLUGS 8OR CAGE SLOTS9 ARE SHAPED TO THROTTLE

FLOW WITH GIVEN CHARACTERSTICS SUCH AS QUIC: OPENING, LINEAR, PARABOLIC OR EQUAL PERCENTAGE "

THREE TYPES OF VALVE CHARACTERESTICS ARE

QUIC: OPENING ;
Th.! "%&e ' #h)()#"e(.!".#! &( *.-e! m)<.m,m #h)$/e .$ '+ 5 ()"e )" + 5e( *)+*e "()*e+!, )! "he &+,/ 6 "" m .! '+)" 5."h ) ').(+% +.$e)( (e+)". $!h.& , &e$.$/ 5."h ) !m)++ !./$)+ 5.++ /.*e "he m)<.m,m '+ 5 ()"e A--.". $)+ .$#(e)!e .$ *)+*e "()*e+ /.*e! !h)(&+% (e-,#e#h)$/e! .$ '+ 5 ()"e . The # mm $ )&&+.#)". $ ' "he *)+*e .! ON -OFF

LINEAR CHARACTERSTICS; Th.! "%&e ' *)+*e &( *.-e! #h)$/e .$ '+ 5 ()"e 5h.#h .! +.$e)( 5."h "he *)+*e +.'". Th)" .! "h.! &( & (". $)+ (e+)". $!h.& &( -,#e! ) #h)()#"e(.!".#! 5."h # $!")$" !+ &e ! "h)" 5."h # $!")$" &(e!!,(e -( & , "he *)+*e /).$ .! "he !)me )" )++ '+ 5 ()"e!. Q = :X

EQUAL PERCENTAGE ;8 => 9 E?,)+ .$#(eme$"! ' *)+*e "()*e+ &( -,#e '+ 5 #h)$/e! 5h.#h )(e e?,)+ &e(#e$")/e ' e<.!".$/ '+ 5 . The #h)$/e .$ '+ 5 ()"e .! )+5)%! &( & (". $)+ " "he '+ 5 ()"e "h)" e<."! @,!" 6e' (e "he #h)$/e .$ *)+*e & !.". $ .! m)-e . Q = QA em< QA = m.$.m,m # $"( ++)6+e '+ 5 ()"e . m = +$ RBT = # $!")$" ' ( ) &)(".#,+)( *)+*e R= ()$/e)6.+."% , T= m)<. *)+*e +.'"

E(u"# Perce!t 5 6 Prese!t &"#ue 7 Pre&ious &"#ue8 3 Pre&ious &"#ue.

9 5 F#o$ R"te

9O 5 Mi! F#o$

9M 5 M"2 F#o$

: 5 V"#&e Tr"&e#

' 5 #! R3T

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R3T

R59M 3 9O

T5*

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, , , , , , , , , ,

*== *== *== *== *== *== *== *== *== *==

=.* =., =.=.? =.> =.< =.@ =.A =.; *.=

-.;* -.;* -.;* -.;* -.;* -.;* -.;* -.;* -.;* -.;*

=.-; =.@A *.*@ *.>< *.;< ,.-> ,.@? -.*-.>, -.;*

>= >= >= >= >= >= >= >= >= >=

>= >= >= >= >= >= >= >= >= >=

* * * * * * * * * *

Linear E !a" #

LIFT8>9
7A 1A 3A CA DA 4A EA FA GA 7AA

LINEAR
7A 1A 3A CA DA 4A EA FA GA 7AA

EQUAL >
1.G4 C.3E 4.CE G.D4 7C.7C 1A.G7 3A.G1 CD.E3 4E.41 7AA

Q.O
AE 1C CD 4F F3 G1 GD GF 7AA 7AA

)** 2* 1* 0*

F L O W

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,* +* )*

)*

,* +* # $% &a"&e $'enin(

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0*

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2*

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I" .! "he $,m6e( ' US /)++ $! &e( m.$,"e ' 5)"e( )" 4A -e/(ee F "h)" 5.++ &)!! "h( ,/h '+ 5 (e!"(.#". $ )" m)<.m,m &e$.$/ m).$").$.$/ ) &(e!!,(e -( & ' 7 &!..

BASIC FLOW RATE FORMULA FOR LIQUIDS IS; 3 4 K5 A5 S3RT 67P)-P+89G: Q=F+ 5 ()"e .$ /&m ( :/Bh( &7=U&!"(e)m &(e!!,(e .$ &!./ ( :/B#m1 &1=D 5$!"(e)m &(e!!,(e .$ &!./ ( :/B#m1 G=S&e#.'.# /()*."% )" (e'e((e- "em&e()",(e := DISCHARGE COEFFICIENT, A = AREA

IF G =7 AND P7-P1 = 7, THEN Q = :HA AS PER THE ABOVE DEFINITION, C* = :HA

NOW Q = C* H SQRT I8P7-P19BGJ WHICH IS THE RELAVENT FORMULA OF FLOW COEFFICIENT OF CONTROL VALVE IN CASE OF LIQUIDS . THE SAME PROCEDURE WILL BE ADOPTED IN CASE OF GAS FLOW , STEAM FLOW ETC. WITH SUITABLE MODIFICATION OF WOR:ING FORMULA.

I" .! e''e#".*e+% )$ .$-e< ' &(e!!,(e (e# *e(% .$ ) # $"( + *)+*e. ..e. H./h C' *)+,e! .$-.#)"e + 5 &(e!!,(e (e# *e(% 5he(e ) + 5 C' *)+,e .$-.#)". $ ' h./h &(e!!,(e (e# *e(% . 5he$ '+,.- '+ 5! "h( ,/h "he *)+*e (.'.#e , "he(e .! ) m)(Ke.$#(e)!e .$ *e+ #."% . Th.! *e+ #."% .$#(e)!e .! )## m&)$.e- 6% &( & (". $)+ -e#(e)!e .$ &(e!!,(e . Ve+ #."% (e)#he! m)<.m,m )$- &(e!!,(e ) m.$.m,m )" "he !m)++e!" #( !! !e#". $)+ '+ 5 )(e) - 5$!"(e)m ' "he (.'.#e )$- "h)" &)(".#,+)( & .$" .! #)++e*e$) # $"()#").

ORIFICEPLATE

--------------------------------------------------------------------------------------------------

VENA CONTRACTA

P1

PRESSURE

P7

PV

VENACONTRACTA VELOCITY

C$n;r$" &a"&e< (i&e 'r$="e>< >ain"? in ;@ree area< )A Ca&i;a;i$n Bi;@ a<<$Cia;e n$i<e anD &i=ra;i$n +A F"a<@in( ,A LeaEa(e $% %"!iD ar$!nD &a"&e <;e>

C $"( + *)+*e !e+e#". $ .! .$ !"e& 5.!e <;e' ) F Ca"C!"a;e CV 7.!e+e#" *)+*e "%&e <;e' + F <e"eC; &a"&e <iGe H ;ri> <iGe anD C@araC;eri<;iC<. S;e' , F <e"eC; enD C$nneC;i$n< 7. E$- # $$e#". $ "%&e 1. E$- # $$e#". $ ()".$/

S;e' - F <e"eC; <ea; "eaEa(e "h)" .! #+)!!7B1B3BCBD. S;e'.F <e"eC; aC;!a;$r ;?'e anD <iGe <;e' /F <e"eC; &a"&e >a;eria"< 7. V)+*e 6 -% m)"e(.)+ 1."(.m m)"e(.)+ 3 !e)" # $!"(,#". $ )! -.#")"e- 6% !e)" +e)K)/e C. G,.-e- 6,!h.$/ D.! '" !e)" m)"e(.)+! ' ( #+)!! *. +e)K)/e

S;e' 0 F <e"eC; 'aCEin( >a;eria" anD =$nne; ;?'e 7.&)#K.$/ m)"e(.)+ )9!")$-)(- Te'+ $ )!6e!" ! 69Te'+ $ *- (.$/ #9G()' .+ 1. 6 $$e" "%&e !")$-)(- B e<"e$-e- B 6e++ 5! !e)+ e<"e$!. $ <;e'1F <e"eC; &a"&e aCCe<<$rie< 7.& !.". $e( 1.! * B * +,me 6 !"e( B ).( !e" B + #K ,& *)+*e B * +,me ")$K B +.m." !5."#h B "()*e+ !" & LLL..e"#

IN GENERAL, ALL MANUFACTURERS HAVE THEIR OWN DESIGN DATA SHEETS, CONSIDERING THE CRITICAL FLOW , CAVITATION , FLASHING AND VALVE NOISE OF THE GIVEN PROCESS CONDITION WHEN THE CALCULATED C* VALUE IS :NOWN, SELECTION AND SIMING OF CONTROL VALVE IS EASY.

AIR FILTER REGULATOR VALVE POSITIONER VOLUME BOOSTER QUIC: EXHAUST AIR LOC: RELAY LIMIT SWITCHES SOLENOID VALVE POSITION TRANSMITTERS

POSITIONER ;
The m).$ ',$#". $ ' & !.". $e( .! " e$!,(e "h)" "he # $"( + *)+*e & !.". $ .! )+5)%! &( & (". $)+ " "he ,$6)+)$#e- ' (#e! ' "he &+,/. "he *)+,e ' # $"( ++e( ,"&," !./$)+ (e/)(-+e!! ' &)#K.$/ 6 < '(.#". $,)#",)" ( h%!"e(e!.!

USAGE OF VALVE POSITIONERF SMOOTH CONTROL CHANGING OF OPERATION MODE ACHIEVING SPLIT RANGE REDUCING TIME LAG CHANGING VALVE CHARACTERSTICS ACTION CAN BE REVERSED BY CHANGING THE PILOT.

SPRING BELLOWS DEFLECTION VALVE

S W O L EL

NOMMLE EXHAUST RELAY VALVE

STRO:E

RESTRICTION IBP SIGNAL

C.V.STEM

FROM NOIILE

TO BELLOWS

CLASS I CLASS II CLASS III CLASS IV CLASS V

NOT SPECIFIED A.D> RATED VALVE CAPACITY A.7 > RATED VALVE CAPACITY A.A7> RATED VALVE CAPACITY

DH7A-Cm+ &e( m.$. OF WATER PER

INCH OF ORIFICE DIAMETER PER PSI DIFFERENTIAL LEA:AGE EXCPRESSED IN ML PER MINUTE VERSUS PORT DIAMETER

CLASS VI

) + +

AVOID

AVOID