A Presentation On Control Valves: G - Sridhar Instrumentation NFCL

A Presentation
on Control Valves
G . SRIDHAR
INSTRUMENTATION
NFCL
NAGARJUNA FERTILIZERS AND CHEMICALS LIMITED
Control Valves
A VALVE IS A DEVICE USED FOR THE CONTROL OF FLUID FLOW
A CONTROL VALVE IS A POWER-OPERATED DEVICE USED TO
MODIFY FLUID FLOW RATE IN A PROCESS SYSTEM.

A VARIABLE ORIFICE
MOST USED FINAL CONTROL ELEMENT IN CLOSED LOOP
Control Valves versus

mechanical valves
Mechanical Valves will be operated by the operator in the
field where as Control Valves can be operated from remote

location.
Mechanical Valves will not achieve fail safe condition, where
as Control Valves will go through the fail safe condition when
required( Fail Open or Fail Close).
Operator intervention will be reduced when using Control
Valves in process system as the parameters( Flow, Level,
Pressure) maintain automatically .
OPEN LOOP
THE OUTPUT SIGNAL HAS NO SELF CORRECTING ACTION WHEN THE
CONTROLLED VARIABLE DOESNT MATCH THE DESIRED VALUE.
CLOSED LOOP
THE OUTPUT SIGNAL HAS SELF CORRECTING ACTION WHEN THE
CONTROLLED VARIABLE DOESNT MATCH THE DESIRED VALUE. THIS IS
DUE TO THE PRESENCE OF A FEEDBACK SIGNAL.
ELEMENTS OF CLOSED LOOP

A CONTROL LOOP HAS THREE MAJOR COMPONENTS
SENSING ELEMENT:
A DEVICE WHICH MEASURES PROCESS VARIABLE.
CONTROLLER:
PROVIDES A CORRECTIVE OUTPUT SIGNAL.
CONTROL VALVE:
THE FINAL CONTROL ELEMENT.
TYPICAL WIRING OF A CLOSED LOOP

CABINET
FIELD
PT
CSS
JB
BARRIER IN
CATP IN
JB
BARRIER OUT
CATP OUT
I/P
PV
DCS
PIC
CONTROL VALVE PARTS
1.Body
2.Yoke
3.Actuator
BODY
IT IS THE PRESSURE CARRYING PART AND
MEETS ALL THE APPLICABLE PRESSURE,
TEMPERATURE AND CORROSION
REQUIREMENTS.
BODY ASSEMBLY CONSISTS OF

HOUSING
BONNET
INTERNAL TRIM
GLAND PACKING
BODY
GLAND
PACKING
BODY FLANGE
STEM WITH
PLUG
INLET
OUTLET
SEAT
TRIM
VALVE TRIM CONSISTS OF
a. PLUG
b. SEAT(S)
c. STEM PLUG GUIDE
d. BUSHINGS
e. CAGE
FUNCTIONS OF TRIM ARE

a. TO PROPORTION THE VALVE ORIFCE AREA AS PER THE
VALVE CHARACTERISTICS
b. TO SHUT OFF TIGHTLY
TRIM MATERIALS
BRONZE
SS-316
SS-316 + STELLITE
440 C SS HARDENED
17-4 PH SS
CERAMIC
HVD
BONNET
ENCASES THE ACTUATOR AND VALVE PACKING

ALLOWS STEM MOVEMENT
DESIGNED TO MEET TEMPERATURE RANGE
IN HIGH TEMPERATURES AND BELOW FREEZING
TEMPERATURE SERVICES, EXTENSION BONNET IS USED
TO ISOLATE THE PACKING
GLAND PACKING
TO PREVENT THE LEAKAGE OF PROCESS FLUID

THROUGH VALVES GLANDS
REQUIREMENT
SHOULD WITHSTAND PROCESS TEMPERATURE
SHOULD NOT REACT WITH PROCEE MEDIUM
GLAND PACKING MATERIALS

ASBESTOS GENERALLY NOT USED NOW
TEFLON - TEMPERATURE RANGE - 40 TO 230 Deg C
TEFLON WITH GLASS FIBER UPTO 455 Deg C IN EXTENDED BONNET
TEFLON IMPREGNATED ASBESTOS - -70 TO 230 DEG C
GRAPHITE
NON- OXIDISING SERVICE- - 15 TO 535 DEG C

OXIDISING SERVICE - - 15 TO 370 DEG C
LAMINATED GRAPHITE RINGS IN EXTENDED BONNET UPTO 650 DEG C
YOKE
A STRUCTURE BY WHICH THE DIAPHRAGM ASSEMBLY IS SUPPORTED
RIGIDLY ON THE BONNET ASSEMBLY.
ACTUATOR BASE
SPRING
ADJUSTMENT
SPRING BASE
NUT
STEM COUPLING
POINTER
TRAVEL SCALE
BONNET BASE
ACTUATOR
UTILISES AIR PRESSURE / ELECTRIC POWER / HYDRAULIC PRESSURE
TO ACT ON A DIAPHRAGM / PISTON AND DEVELOP A FORCE TO
MOVE THE ACTUATOR STEM.
ACTUATOR PARTS
VENT
DIAPHRAGM
PLATE
DIAPHRAGM
CASINGS
DIAPHRAGM
INPUT SIGNAL
ACTUATOR
SPRING
ACTUATOR STEM
SPRING SEAT
YOK
E
INDICATOR
GLAND STUDS
STUFFING BOX
SPRING ADJUSTER
STEM CONNECTOR
INDTR. SCALE
LOCK NUT
BONET FLANGE
TYPES OF ACTUATOR
DIFF. PRES
AREA
SPRING RATE
WORKING PRINCIPLE
STEM
TRAVEL
VARIABLE AIR PRESSURE IS APPLIDE TO A FLEXIBLE DIAPHRAGM TO

OPPOSE A SPRING. THE COMBINATION OF DIAPHRAGM AND SPRING
FORCES ACTS TO BALANCE THE FLUID FORCES ON THE VALVE
THE FOLLOWING EQUATION CAN BE DERIVED FROM A

SUMMATION OF FORCES ON THE VALVE PLUGS ADOPTING THE
POSITIVE DIRECTION ,DOWNWARD .
(STADY STATE EQUATION) PA - KX - PV AV = 0
PRES.
DROP.
AV
PV
EFFECTIVE INTRANAL
VALVE AREA
EQUATION APPLIES TO A PUSHDOWN TO CLOSE ACTUATOR

AND VALVE COMBINATION WITH FLOW UNDER THE PLUG.
- PA + KX + PV AV = 0
CONTROL VALVE TYPES

THERE ARE TWO BASIC TYPES OF CONTROL
VALVE
A) ROTARY MOTION VALVES
B) LINEAR MOTION VALVES
Control Valve Classification

Control
Valve
Linear
Motion
Globe
Single
Seated
Rotary
Motion
Globe
Diaphragm
Angle
3 way
Double
Seated
Ball
Butterfly
LINEAR MOTION
TYPES OF CLOSURE
1. GLOBE
2. DIAPHRAGM
APPLICATIONS
i.
GENERAL AND EXTREME SERVICES

SUITED TO HIGH PRESSURE AND TEMPERATURE APPLICATION
CAN HANDLE FLASHING,CRYOGENIC,GUMMY FLUIDS
LOW RECOVERY
CAN THROTTLE SMALL FLOW RATES
OFFERS VARIETY OF SPECIAL TRIM DESIGNS
ii.
iii.
iv.
v.
vi.
GLOBE VALVES
ADVANTAGES
SIMPLICITY OF ACTUATOR DESIGN
WIDE RANGE OF VALVE CHARATERISTICS
LOW LIKLIHOOD OF CAVITATION AND NOISE
WIDE RANGE OF SPECIAL DESIGNS FOR CORROSIVE, ABRASIVE
HIGH TEMPERATURE AND HIGH PRESSURE APPLICATIONS
LINEAR RELATIONSHIP BETWEEN CONTROL SIGNAL AND
VALVE STEM MOVEMENT
SMALL DEADBAND/HYSTERISIS
CAN BE USED WITHOUT POSITIONERS
DISADVANTAGES
HIGHER COST
LOWER CAPACITY
HIGHER GLAND LEAKAGES
GLOBE VALVES
VARIOUS TYPES OF GLOBE VALVES
SINGLE SEATED
DOUBLE SEATED
CAGE GUIDED
SPLIT-BODY
ANGLE VALVES
THREE WAY VALVES
SINGLE SEATED VALVES

MOST WIDELY USED
AVAILABLE IN WIDE VARIETY OF
CONFIGURATIONS
GOOD SHUT-OFF CAPABILITY
EASY TO MAINTAIN
GUIDING
TOP GUIDED
SINGLE SEATED VALVES

1 Plug Stem
GLOBE TYPE
2 Packing Flange Stud

3 Packing Flange Nut
4 Packing Flange
5 Packing Follower
6 Packing
7 Lantern Ring (Optional)
8 Valve Bonnet
9 Body Stud
10 Body Stud Nut
11 Body Gasket
12 Guide Bushing
13 Cage (2)
14 Seat Ring
15 Seat Ring Gasket
16 Plug
17 Plug Pin
18 Valve Body
19 Drive Nut
DOUBLE SEATED VALVES

LARGER AND HEAVIER THAN
SINGLE SEATED DESIGN
POOR SHUT OFF

SEMI-BALANCED HENCE SMALLER
ACTUATOR SIZE
AIR TO OPEN OR AIR TO CLOSE
CONFIGUTATIONS CAN BE
CHANGED EASILY TO THE
REQUIRED VALVE FAILURE
NOT WIDELY USED
DOUBLE SEATED VALVES

1 Valve Plug Stem
2 Packing Flange Nut
3 Packing Flange
4 Packing Flange Stud
5 Drive Nut
6 Bonnet
7 Body
8 Plug Pin
9 Valve Plug
10 Blind Flange
11 Valve Body Stud Nuts
12 Valve Body Studs
13 Valve Body Gasket
14 Guide Bushing
15 Lower Seat Ring
16 Upper Seat Ring
17 Packing
18 Packing Spacer
19 Packing Follower
CAGE VALVES
IMPROVED STABILITY WITH MASSIVE
PLUG GUIDING OVER THE ENTIRE STROKE
MOST POPULAR DESIGN
EASY TO CHANGE THE TRIM
DIFFERENT TRIMS SUCH AS ANTICAVITATION, LOW NOISE TRIMS
AVAILABLE
OVERALL DESIGN IS VERY RUGGED
CAN HANDLE HIGH PRESSURE DROP
APPLICATIONS
BETTER SHUT OFF DUE TO PROCESS
PRESSURE ACTING ON THE PLUG
GUIDING
STEM OR TOP GUIDING
CAGE GUIDED
CAGE
TYPE
THREE WAY VALVE

o
HIGH FLOW CAPACITY
USED FOR MIXING AND

DIVERTING FLUID.
HIGH RANGEABILITY
LEAKAGE CAPABILITY
CONSISTENT WITH NORMAL
SINGLE SEATED GLOBE
VALVE.
ANGLE VALVES
EROSION APPLICATIONS
FLASHING APPLICATIONS
HIGH PRESSURE DROP APPLICATIONS
TO AID SPECIAL PIPING ARRANGEMENT TO AID
DRINAGE
ANGLE
TYPE
SPLIT-BODY VALVES
VARIANT OF SINGLE SEAT VALVE
USED IN SLURRY, GUMMY AND

CORROSIVE SERVICES
BODY CAN BE EASILY DISSEMBLED FOR
MAINTENANCE
BODY FLANGE IS PRONE TO LEAKAGES
CANNOT BE WELDED IN PIPELINE

BECAUSE MAINTENANCE REQUIRES
BODY SEPARATION
NOT WIDLY USED
DIAPHRAGM VALVES
NO LEAKAGE
SELF-CLEANSING
CORROSION RESISTANT
MATERIAL CAN BE USED TO

PROVIDE LINING
CAPACITY OF LINED VALVES WILL
BE ABOUT 25% LESS THAN
UNLINED VALVES
USED IN CORROSIVE, TOXIC
APPLICATIONS
LIMITED PRESSURE AND
TEMPERATURE CAPABILITIES
POOR CONTROL OVER 50%
OPENING
ROTARY MOTION
TYPES OF CLOSURE
1. BALL
2. BUTTERFLY
FEATURES
i.
STREAMLINED FLOW PATH

HIGH RECOVERY
MORE CAPACITY
LESS PACKING WEAR
CAN HANDLE SLURRY AND ABRASIVES
INTEGRAL BONNET
HIGH RANGEABILITY
ii.
iii.
iv.
v.
vi.
vii.
ROTARY MOTION VALVES
BALL VALVES
ADVANTAGES
MODERATE COST (COMPARED WITH GLOBE)
HIGHER FLOW CAPACITY ( 2 - 3 TIMES OF GLOBE)
BETTER SHUT-OFF,WIDE RANGEABILITY
LOW STEM LEAKAGE
CAN PROVIDE NEAR =% CHARACTERISTIC
DISADVANTAGES
HIGH PRESSURE RECOVERY LEADS TO INCREASES THE
CHANCES OF CAVITATION AND NOISE LEVEL

ACTUATOR NEEDS TO BE OVERSIZED BECAUSE OF
HIGH BREAK TORQUE REQUIREMENT.
VULERANABLE TO SEAL WEAR
HIGH TORQUE AND HIGH FRICTION
BALL VALVES
APPLICATIONS
SLURRIES
ON-OFF CONTROL
LARGE LINE SIZE
PIGGING SERVICES
LOW PRESSURE DROP REQ.
BUTTERFLY VALVES
ADVANTAGES
LOWER COST (COMPARED WITH GLOBE)
HIGHER FLOW CAPACITY ( 2 - 3 TIMES OF GLOBE)
REDUCED EROSION
WIDE RANGEABILITY
CAN PROVIDE NEAR =% CHARACTERISTIC
LOW FRICTION
DISADVANTAGES
HIGH PRESSURE RECOVERY LEADS TO LOW VENA
CONTRACTA PRESSURE, INCREASES THE CHANCES OF

CAVITATION AND NOISE
DUE TO HIGH CAPACITY, IT HAS THE TENDENCY OF SMALL
VALVE IN LARGE PIPE, LEADS TO HIGHER PRESSURE DROP
ACTUATOR NEEDS TO BE OVERSIZED BECAUSE OF HIGH
BREAK TORQUE REQUIREMENT.
HIGH LEAKAGES
CANNOT BE USED WITHOUT POSITIONERS
BUTTERFLY VALVES
APPLICATIONS
GENERAL SERVICE
LARGE LINE SIZE
VISCOUS LIQUID
EQUAL PERCENTAGE FLOW
CHARACTERSTICS
THROTTLING AND ON-OFF
SERVICE
HIGH TEMPERATURE AND SOME
SLURRIES.
TYPES OF CONTROL VALVES

(BASED ON flow CHARACTERISTICS)
Q
U
I
LINEAR
QUICK OPENING
EQUAL PERCENTAGE
A
R
C
K
O
P
E
N
I
N
FLOW CHARACTERSTICS
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 IN A CERTAIN MANNER
FLOW CHARACTERSTICS
QUICK OPENING :
THIS TYPE OF CHARACTERSTICS PROVIDES MAXIMUM CHANGE IN
FLOW RATE AT LOWER VALVE TRAVELS
AS THE PLUG BOTTOM IS FLAT WITH A FAIRLY LINEAR
RELATIONSHIP , SO THE OPENING WITH A SMALL SIGNAL WILL GIVE
THE MAXIMUM FLOW RATE
THE COMMON APPLICATION OF THE VALVE IS ON -OFF
FLOW CHARACTERSTICS
LINEAR CHARACTERSTICS:
Linear trim provides equal increases in flow rate for equal increases in
plug lift. Thus the flow rate is linear with plug position throughout its
travel. This type of trim should be specified if the control valve is to
absorb most of the system pressure drop.
FOR FLOW AND LEVEL CONTROL SERVICE
CONSTANT PRESSURE DROP ACROSS THE VALVE
MAJOR PRESSURE DROP IS NOT THROUGH THE VALVES
FLOW CHARACTERSTICS
EQUAL PERCENTAGE :
Equal percentage trim provides equal percentage increase in rate of
flow for equal increments of plug lift. In this case small flow passes
correspond to large changes in lifts as the plug first leaves the seat
and vice-versa towards the full position.
THUS CHANGE IN FLOW IN FLOW RATE IS ALWAYS

PROPORTIONAL TO THE FLOW RATE THAT EXISTS JUST
BEFORE THE CHANGE IN VALVE POSITION IS MADE
MAJOR PORTION OF SYSTEM PRESSURE DROP IS NOT

THROUGH VALVE AND VARIABLE PRESSURE DROP
ACROSS THE VALVE
FOR TEMPERATURE ,FLOW AND PRESSURE CONTROL

LOOPS
FLOW CHARACTERSTICS
The formula which establishes the equal percentage flow characteristic is
Q = QO emX
Q = Flow Rate
QM = Maximum Controllable Flow
QO = Minimum Controllable Flow
QO = Minimum Controllable Flow
X = Valve Travel or Lift
m = Constant depends on R and T
R = Rangability = Q M / Q0
T = Maximum Valve Travel
Equal
Q = Flow QO =
Percent = (
Rate
Min
Present value
Flow
- Previous
value) /
Previous
value.
0.48
0.48
0.48
0.48
0.48
0.48
0.48
0.48
0.48
2.96
4.37
6.47
9.56
14.14
20.91
30.92
45.73
67.62
100.00
2
2
2
2
2
2
2
2
2
2
QM =
Max
Flow
100
100
100
100
100
100
100
100
100
100
X = Valve
Travel
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1.0
m = ln R/T
3.91
3.91
3.91
3.91
3.91
3.91
3.91
3.91
3.91
3.91
mX
0.39
0.78
1.17
1.56
1.96
2.35
2.74
3.13
3.52
3.91
R/T
50
50
50
50
50
50
50
50
50
50
R=QM / T = 1
QO
50
50
50
50
50
50
50
50
50
50
1
1
1
1
1
1
1
1
1
1
FLOW CHARACTERSTICS
LIFT
10
20
30
40
50
60
70
80
90
100
LINEAR
10
20
30
40
50
60
70
80
90
100
EQUAL %
2.96
4.37
6.47
9.56
14.14
20.91
30.92
45.73
67.62
100
Q.O
07
24
45
68
83
92
95
98
100
100
FLOW CHARACTERSTICS
PROBLEMS IN CONTROL VALVES

MAJOR PROBLEMS IN CONTROL VALVE DESIGN ARE
CAVITATION
FLASHING
NOISE
CAVITATION
Cavitation occurs as two stage phenomenon. when pressure inside the valve
falls below the vapour pressure, then continuity of flow is broken by the
formation of vapour bubbles. When pressure recovers above the vapour
pressure (i.e if outlet pressure in greater than vapour pressure) ,the vapour
bubbles revert back to liquid ,which release large amount of energy.
These collapsing of vapour bubbles cause localized pressures and cause rapid
wear of valve trim & body at high pressure drop conditions. It also leads to
annoying noise & vibration.
P1 UPSTREAM PRESSURE
P2 - DOWNSTREAM PRESSURE
EFFECTS OF CAVITATION
INCREASED NOISE
VIBRATION IN THE PIPING SYSTEMS
DAMAGE TO VALVE
UNDER SERVERE CAVITAING CONDITIONS EXTREMELY
HARD CONTROL VALVE COMPONENTS HAVE FAILED
IN A MATTER OF HOURS
REDUCE CAPACITY OF THE VALVE
SINCE VAPOR BUBBLES FLOW IN PORT, THE DENSITY
OF FLUID DECREASED, WHICH LEADS TO REDUCED
FLOW
HOW TO OVERCOME CAVITATION

1. PRESSURE DROP STATGING:
a. Can be prevented by reducing pressure in stages
b. Forces the fluid through a series of restrictions
c. Each restriction dissipates a certain amount of energy
d. Divides the pressure drop equally
e. Ensures a flow path with pressure recovery
HOW TO OVERCOME CAVITATION

2. EXPANDING FLOW AREA:
a. Features multi path multi stage designs
b. The stage wise pressure drop reduces progressively towards the last stage.
3. CONVENTIONAL CONTROL INSTEAD OF PREVENTION
a. Use of harder materials such as 17-4 PH,440 C ,Stellite hard facing etc.
CAVITATION
FLASHING
Flashing is a process in which the pressure of the liquid falls below the vapour
pressure thus leading to the formation of vapour bubbles. If the downstream
pressure is less than vapour pressure, the bubbles will not collapse back into
liquid and subsequent flow will be two phase consisting partly of liquid and
partly vapour.
Flashing leads to high flow velocities which can damage both the trims and the
body (sand blasting effect ).
EFFECTS OF FLASHING
Same effects as Cavitation but with more intensity.
Flashing is classified as a process requirement and hence cannot
be eliminated.
Effects of Flashing can be reduced by following methods.
a. Providing higher size valve to reduce the velocity

b. Providing hardened body/trim material, to resist against
erosion.
NOISE
There are basically three types of Noises.
Mechanical Vibration:
It is caused by the response of internal components within a valve to

turbulent flow through the valve.
Aerodynamic Noise:
It is a direct result of the conversion of the mechanical energy of the flow
into acoustic energy as the fluid passes through the valve restrictions.
Hydrodynamic Noise
Liquid flow Noise, Cavitation Noise, and Flashing Noise can be generated
by the flow of a liquid through a valve and piping system.
METHODS TO REDUCE NOISE

Cavitation Noise can be eliminated by preventing Cavitation by special designs.
(Low DB Anti Cavitation Valves ).
Path Treatment:
Increasing Pipe Schedule: An increase in pipe schedule is an effective means
to reduce control valve noise.
Increasing Pipe Insulation: Insulation with sufficient pipe thickness
effectively reduces control valve noise or radiated noise.
In Line Silencers: In Line Silencers are effective in reducing noise as they
installed directly downstream of the valve. These silencers dissipate the
noise within the fluid stream .
Source Treatment:
Adiabatic flow with friction: It is to reduce pressure much like that pressure
loss which occur in a long pipeline . This effect is produced by letting the
fluid pass through the number of restrictions providing torturous flow
pattern dissipating energy through high head loss rather than through
shock waver.
FLOW COEFFICIENT (Cv)

DEFINITION
Cv is the number of U. S. gallons per minute of water that will
pass through a given flow restriction with a pressure drop of one
psi at 60 Deg F
It is a capacity index upon which the engineer can rapidly and
accurately estimate the required size of a restriction in any fluid

system.
Cv FOR LIQUID SERVICE
Cv=Q/sqrt((P1-P2)/G)
Q - flow rate
P1 upstream pressure
P2 - downstream pressure
G Specific Gravity at referred temperature
CONTROL VALVE
SELECTION AND SIZING
Cv DEPENDS ON PORT SIZE
FLOW (MAX & MIN)
SPECIFIC GRAVITY
TEMPERATURE
PRESSURE
BODY MATERIAL
PRESSURE
TEMPERATURE
FLUID
BODY RATING
PRESSURE
TEMPERATURE
LEAKAGE CLASS
AS PER PROCESS REQ.
BODY TYPE
FAILURE POSITION
PACKING MATERIAL
TEMPERATURE
FLUID
TRIM SELECTION
FLOW CHARACTERISTICS
CAVITATION AND NOISE
PRESSURE DROP ACROSS VALVE
PRESSURE BODY RATING
END CONNECTIONS
WELDED OR FLANGED
LINE SIZE
ACCESSORIES REQUIREMENT
LIMIT SWITCHES
I/P CONVERTERS OR ELECTRO

PNEUMATIC POSITIONERS
SOLINOID VALVES
AIR FILTER REQULATER ASSEMBLY
POSITION TRANSMITTER
HAND WHEEL
ACCUMULATOR
AIR LOCK RELAYS
PRESSURE RATINGS & TEMPERATURE

CONSIDERATIONS
CONSIDERED AS PER ANSI
PRESSURE CLASSES
EACH CLASS HAVE
MAXIMUM PRESSRUE
WHICH DECREASE WITH
TEMPERATURE
MINIMUM AND
MAXIMUM TEMPERATUE
BASED AND DUCTILITY
AND STRENGTH
STRENGTH AND
DUCTILITY OF MATERIAL
RELATIVE THERMAL
EXPANSION OF OTHER
PARTS
DISINTEGRATION OF
SOFT PARTS
(ELASTEMERS, PLASTICS &
TFE)
VALVE BODY MATERIAL

SELECTION CRITERIA
CORROSION BY THE PROCESS FLUID
EROSION BY ABRASIVE MATERIAL
CAVITATION AND FLASHING SERVICES
USUALLY PIPE MATERIAL INDICATES BODY MATERIAL,
HOWEVER DUE TO HIGHER VELOCITY OFTEN PIPE AND
VALVE MATERIALS DIFFER
CONTROL VALVE LEAKAGE CLASS

CLASS I
NOT SPECIFIED
CLASS II
0.5% RATED VALVE CAPACITY
CLASS III
0.1 % RATED VALVE CAPACITY
CLASS IV
0.01% RATED VALVE CAPACITY
CLASS V
5*10-4ml per min. OF WATER PER

INCH OF ORIFICE DIAMETER PER
PSI DIFFERENTIAL
CLASS VI
LEAKAGE EXCPRESSED IN ML PER

MINUTE VERSUS PORT DIAMETER
ACCESSORIESN OF THE CONTROL

VALVES
AIR FILTER REGULATOR
VALVE POSITIONER
VOLUME BOOSTER
QUICK EXHAUST
AIR LOCK RELAY
LIMIT SWITCHES
SOLENOID VALVE
POSITIONERS
A device attached to an actuator that receives an electronic or pneumatic
signals from the controller and compares this signal to the actuators
position.
A HIGH-GAIN PROPORTIONAL CONTROLLER WHICH COMPARES

THE INPUT SIGNAL (SET POINT) WITH VALVE POSITION
(PROCESS VARIABLE)AND CORRECTS INACCURACIES
THE GAIN CAN BE ADJUSTED
REASONS TO USE POSITIONERS
Increase control system resolution

i.e)fine resolution.
Allow use of characteristic cams.
Packing Box Friction, Actuator Hysteresis, Corrosion, Lack of Lubrication,

Unbalanced forces in Plug, Non linearity's in valve actuator will not have
impact on valve accuracy.
Allow Split Ranging.
Overcome seating friction in rotary valves.
Facilitate operation when the higher number in the bench-set range is greater
than 1ksc
Permit use of piston actuators
Allow distance between controller and control valve using the advantage of 420ma signal
Action of the valve can be reversed
SOLENOID VALVES
Solenoid valves are used to bring the Control valve to the fails safe state
condition (i.e. Fail Open or Close) by venting the air from the Actuator.
Application : Used in all Control Valves where Fail Safe State is required.
VOLUME BOOSTER
Volume Boosters are used to increase the air flow to and from an actuator
beyond the capacity of the usual positioner.
The output Pressure is same as the inlet pressure
To be most effective ,the booster should be located near the actuator and
connected to it by tubing at least 3/8 inches in diameter.
Applications: Fast throttling action is required, Big size Actuators ,
Antisurge Control Valves.
QUICK EXHAUST
Quick Exhaust valves are used to increase the Control valve stroking speed
(open or close) fully in only one direction.
The Same process can be achieved with Solenoid valves ,but the speed is less.
It is used only for full opening or closing , controllable stroking speed can be
achieved through Volume Boosters.
Applications: Antisurge Control Valves, Vent Valves
AIR LOCK RELAY

When the supply pressure falls below a value set by the spring the Air Lock
valve closes and locks the air in the Actuator.
This makes the Control valve opening position holds at the same position
before air supply failed.
Trip relay is similar to Air Lock relay. It is used to allow air from a local
reservoir to drive the actuator to the safe position when the air supply fails.
Applications: Piston Type Actuators to achieve Fail state
Control valves orientation
THANK YOU
G . SRIDHAR
INSTRUMENTATION
NFCL

A Presentation On Control Valves: G - Sridhar Instrumentation NFCL

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A Presentation

NAGARJUNA FERTILIZERS AND CHEMICALS LIMITED

MODIFY FLUID FLOW RATE IN A PROCESS SYSTEM.

NAGARJUNA FERTILIZERS AND CHEMICALS LIMITED

Control Valves versus

field where as Control Valves can be operated from remote

NAGARJUNA FERTILIZERS AND CHEMICALS LIMITED

NAGARJUNA FERTILIZERS AND CHEMICALS LIMITED

NAGARJUNA FERTILIZERS AND CHEMICALS LIMITED

ELEMENTS OF CLOSED LOOP

NAGARJUNA FERTILIZERS AND CHEMICALS LIMITED

TYPICAL WIRING OF A CLOSED LOOP

CONTROL VALVE PARTS

BODY ASSEMBLY CONSISTS OF

NAGARJUNA FERTILIZERS AND CHEMICALS LIMITED

FUNCTIONS OF TRIM ARE

NAGARJUNA FERTILIZERS AND CHEMICALS LIMITED

NAGARJUNA FERTILIZERS AND CHEMICALS LIMITED

ENCASES THE ACTUATOR AND VALVE PACKING

NAGARJUNA FERTILIZERS AND CHEMICALS LIMITED

TO PREVENT THE LEAKAGE OF PROCESS FLUID

SHOULD WITHSTAND PROCESS TEMPERATURE

SHOULD NOT REACT WITH PROCEE MEDIUM

GLAND PACKING MATERIALS

NON- OXIDISING SERVICE- - 15 TO 535 DEG C

NAGARJUNA FERTILIZERS AND CHEMICALS LIMITED

NAGARJUNA FERTILIZERS AND CHEMICALS LIMITED

NAGARJUNA FERTILIZERS AND CHEMICALS LIMITED

NAGARJUNA FERTILIZERS AND CHEMICALS LIMITED

NAGARJUNA FERTILIZERS AND CHEMICALS LIMITED

VARIABLE AIR PRESSURE IS APPLIDE TO A FLEXIBLE DIAPHRAGM TO

THE FOLLOWING EQUATION CAN BE DERIVED FROM A

EQUATION APPLIES TO A PUSHDOWN TO CLOSE ACTUATOR

CONTROL VALVE TYPES

NAGARJUNA FERTILIZERS AND CHEMICALS LIMITED

Control Valve Classification

NAGARJUNA FERTILIZERS AND CHEMICALS LIMITED

GENERAL AND EXTREME SERVICES

NAGARJUNA FERTILIZERS AND CHEMICALS LIMITED

NAGARJUNA FERTILIZERS AND CHEMICALS LIMITED

NAGARJUNA FERTILIZERS AND CHEMICALS LIMITED

VARIOUS TYPES OF GLOBE VALVES

NAGARJUNA FERTILIZERS AND CHEMICALS LIMITED

SINGLE SEATED VALVES

NAGARJUNA FERTILIZERS AND CHEMICALS LIMITED

SINGLE SEATED VALVES

2 Packing Flange Stud

DOUBLE SEATED VALVES

POOR SHUT OFF

NAGARJUNA FERTILIZERS AND CHEMICALS LIMITED

DOUBLE SEATED VALVES

NAGARJUNA FERTILIZERS AND CHEMICALS LIMITED

THREE WAY VALVE

HIGH FLOW CAPACITY

USED FOR MIXING AND

NAGARJUNA FERTILIZERS AND CHEMICALS LIMITED

USED IN SLURRY, GUMMY AND

CANNOT BE WELDED IN PIPELINE

NAGARJUNA FERTILIZERS AND CHEMICALS LIMITED

MATERIAL CAN BE USED TO

NAGARJUNA FERTILIZERS AND CHEMICALS LIMITED

STREAMLINED FLOW PATH