1224 IEEE TRANSACTIONS ON INSTRUMENTATION AND MEASUREMENT, VOL. 48, NO.

6, DECEMBER 1999

A Novel Method of Using a Control Valve

for Measurement and Control of Flow
M. A. Atmanand and M. S. Konnur

Abstract—The control of flow through a pipe requires mainly
three devices—a flowmeter for the measurement of flow, a control
valve to control the flow, and a controller. The controller gives
an appropriate signal to the control valve depending upon the
difference between the measured flow rate and the set flow
rate. Conventional flowmeters produce a differential pressure
in the flow, which is measured and suitably scaled to get the
flow rate. Incidentally, a control valve uses the principle of
restricting the area for flow which in turn produces a differential
pressure. From the above, it is seen that if a relationship is
developed between the differential pressure produced by the
control valve and the flow through it, the valve itself could
function as a flow meter also, apart from acting as a control valve.
A relationship for this was established based on the equation
for control valve capacity (Cv ) for different valve positions. The
expression requires knowledge of the differential pressure across
the valve, the static pressure, temperature, the valve position,
and the Cv Vs valve position characteristics in order to measure
and control the flow rate. Error analysis is performed for the
expression and to suggest means to improve the accuracy level. An
iterative approach is necessary in order to obtain a particular flow
rate using this method. This necessitates the use of a computer
or a processor-based system, similar to present day intelligent
controllers, to implement the scheme. A prototype was made in
the laboratory using a 50-mm conventional control valve with
pneumatic actuator, working as the control valve and flowmeter.
An HP data acquisition and control system (DACS), used as the
controller, was also used to provide the appropriate output signal
to achieve the necessary flow control. The unit was calibrated at
the air flow laboratory to an accuracy of 61:5%.
I. INTRODUCTION
M EASUREMENT and control of fluid flow is very much
essential in any process-control plant. Many types of
flowmeters, both inferential and noninferential, have evolved
over the years [1]. Flowmeters which produce a differential
pressure in the flow, which in turn is related to the flow rate,
were some of the first kind of flow meters [2]. Orifice plates,
venturi meters, and the like fall into this category [3]. Due to
the advent of modern electronics, many types of flow meters
like the electromagnetic flowmeter, coriolis mass flowmeter,
cross-correlation flow meter, etc., have been developed and
are widely used in process plants [4]. The major advantage
of some of the latest flowmeters is that they do not introduce
a differential pressure for measurement of flow unlike their
conventional counterparts. This amounts to a saving in energy
for pumping of the fluids.
Manuscript received February 1, 1998; revised September 16, 1999.
M. A. Atmanand is with the National Institute of Ocean Technology, Indian
Institute of Technology, Madras 600 036, India (e-mail: atma@niot.ernet.in).
M. S. Konnur is with the Fluid Control Research Institute, Palghat 678 623,
India.
Publisher Item Identifier S 0018-9456(99)09593-5.
0018–9456/99$10.00  1999 IEEE
For the control of fluid flow, it is essential to introduce
a variable restriction in the flow. A control valve precisely
does this [5]. Control valves were in use for a very long time,
beginning perhaps from the time when dams and irrigation
systems were first designed [6]. Even though, due to advances
in mechanical engineering, many of the latest types of control
valves have been developed, the basic principle of the control
valve (i.e., introducing a variable restriction in the flow) has
remained the same. This method of flow control introduces a
differential pressure across the control valve.
II. PRINCIPLE
For a fluid flow control loop, however sophisticated a
flowmeter is, it is essential to have a control valve that
operates in a conventional way. Thus, in a flow control loop, a
differential pressure is generated across the system due to the
control valve. If this differential pressure itself can be related
to the flow rate through the valve, then the flowmeter can
be entirely eliminated from the flow control loop. This idea
has been developed mathematically and experimentally. Even
though the idea can be implemented for all types of fluid flow
control, for the sake of this paper only, flow control of air is
considered.
The flow rate through a conventional differential
pressure-producing flowmeter is given by
(1)
where is the discharge coefficient, and is the differ-
ential pressure measured across the meter. Fig. 1 shows the
schematic of a conventional flow control loop.
A salient parameter of a control valve, called the control
valve capacity states that the flow capacity of a valve is the
U.S gallons per minute of water at a temperature of 60 F that
will flow through the valve with a pressure loss of one pound
per square inch at a specific opening [7]. Even though the units,
for the sake of definition, are given in the foot-pound-second
(FPS) system, they are appropriately converted to SI units for
the purpose of calculations. For the valve in the fully open
condition, for compressible fluid flow, the equation relating the
control valve capacity to the flow rate , differential pressure
across the valve, static pressure , temperature in
the line, expansion factor , compressibility factor and
gas specific gravity for compressible fluid is given by
(2)
where and is a numerical constant to take care
of the appropriate units [8].
ATMANAND: NOVEL METHOD OF USING A CONTROL VALVE
Fig. 1. Conventional flow control loop.
Fig. 2. Block schematic of valve acting as flow meter.
The value varies with respect to the position of the valve.
From (2), one can get
(3)
From the above equation, the flow rate at a particular valve
opening can be calculated if the for that opening and
the various other measured parameters and constants are
substituted in (3).
III. METHOD OF IMPLEMENTATION
The for the control valve is determined by testing it
in a laboratory, for various valve openings. The differential
pressure, static pressure, temperature and position of the
control valve stem are measured for this purpose.
When the valve is used also as a flowmeter, the for that
particular valve opening is determined from the calibration
data already available. From this , the actual flow rate is
computed from (3) after measuring the differential pressure,
static pressure, etc. As in the conventional flow control system,
the difference between actual flow rate and set flow rate is
calculated, and the valve is moved such that the difference
is minimized. Fig. 2 shows the block schematic of the valve
acting as flowmeter.
IV. EXPERIMENTAL RESULTS
For the purpose of verifying the scheme explained, a con-
ventional plug-type control valve of 50-mm size with a pneu-
matic actuator and electro-pneumatic positioner was used.
The position characteristics were determined by the
gravimetric method at the water flow laboratory. The control
valve was then connected in the air flow laboratory pipe lines
for implementation of the scheme described.
A capacitance-type differential pressure transmitter of ac-
curacy % was connected across the control valve for
1225
TABLE I
CALIBRATION RESULTS OF PROTOTYPE FLOWMETER
measurement of differential pressure. The static pressure was
measured using a capacitance-type pressure transmitter with
an accuracy of %. The temperature was measured using
a resistance temperature detector (RTD) with an accuracy
better than %. The valve stem position was measured
using a spring-loaded linear variable differential transformer
(LVDT) with an accuracy of mm. The valve stroke
was of the order of 25 mm. The signals proportional to the
above parameters were connected to a PC-based Hewlett-
Packard data acquisition and control system (DACS). The
data acquisition and computations were performed using the
DACS, and the control signal for operating the control valve
was given from the DACS to the electro-pneumatic positioner
of the control valve for operating the same.
V. ERROR ANALYSIS
Error analysis performed on (3) yields the maximum ab-
solute error in the measurement of flow using this novel
method:
(4)
From the above equation, it can be seen that the contributions
of the errors due to measurement of pressure, differential
pressure, and temperature have a lesser influence due to the
multiplying factor of associated with these terms. The
major contribution to the overall error is due to which is
a function of valve position. However, based on experiments
in the laboratory, the error contribution due to is due to
more than one factor.
One error component is due to the error in reading data
from the . position graph stored in the system. Being
a PC-based system, the effect of this error can be neglected
compared with the other major contributors. The next error
component is the error involved in determining the char-
acteristics of the valve. This in turn is determined by the
uncertainty of measurement instruments used in the laboratory
where the characteristics were determined. Another is due to
the error in reading the position of the valve stem and thus
depends on the position transducer used.
For the experiments performed with transducers having the
accuracies mentioned above and a laboratory uncertainty of
%, the maximum accuracy obtainable is % for the
system.
1226 IEEE TRANSACTIONS ON INSTRUMENTATION AND MEASUREMENT, VOL. 48, NO. 6, DECEMBER 1999
TABLE II
COMPARISON OF COMPONENT REQUIREMENTS FOR NORMAL FLOW CONTROL LOOP AND FOR THE PROTOTYPE DEVELOPED
VI. RESULTS
The system developed was calibrated at the air flow lab-
oratory of the Institute against a servo positive-displacement
flowmeter having an accuracy of %. An overall accuracy
of the order of % was obtained for the system. Table I
shows the results obtained. As seen from the error analysis, the
major cause of the error is due to the errors involved in the
measurement of differential pressure, pressure, and position.
By using transmitters of higher accuracy, the overall accuracy
can be improved.
VII. CONCLUSION
A novel system that utilizes the inherent pressure drop
available across a conventional control valve for measurement
and control of flow is described. This system eliminates the
use of a conventional flowmeter in a flow control loop. While
the system works satisfactorily under laboratory conditions, its
use in a process-control plant is yet to be established. The eco-
nomic gain, using this scheme instead of the conventional flow
control loop, can be evaluated from Table II. The accuracies
are comparable with conventional systems. However, for better
accuracy, it is to be calibrated with standard instruments with
higher levels of accuracy. The additional pressure drop and
the consequent power loss due to the conventional flowmeter,
when used in a flow control loop, are absent in this case.
The marginal additional cost, which may accrue due to the
additional controller, will be compensated by the savings in
recurring costs for power, due to the absence of a conventional
flowmeter.
Even though the system developed uses a conventional PC-
based data acquisition system, this unit can be replaced by a
microprocessor-based system having capabilities to acquire the
various data, perform the necessary computation, and provide
appropriate signals for actuating the control valve. This system
as described could also be modified for gas flow measurement
in custody transfer, wherein the flow rate measured is to be
converted to the standard temperature and pressure (STP) or
the normal temperature and pressure (NTP) condition. The
necessary equations derived from the gas law could be fed
into the system. This processor-based system, installed in the
field, could be integrated with the field-bus system, which is
being standardized internationally.
REFERENCES
[1] A. T. J. Hayward, Flowmeters—A Basic Guide and Source Book for
Users, 1st ed. New York: McMillan, 1979.
[2] R. W. Miller, Flow Measurement Engineering Hand Book. New York:
McGraw Hill, 1983.
[3] “Measurement of fluid flow by means of orifice plates, nozzles and
venturi tubes inserted in circular cross-section conduits running in full,”
Int. Stand. Organ. ISO 5167-1980.
[4] Instrumentation Reference Book, Noltingk, Ed., 1st ed. London, U.K.:
Butterworth, 1988.
[5] J. L. P. E. Lyons, Lyons Valve Designers Handbook. New York: Van
Nostrand Reinhold, 1982.
[6] Water Measurement Manual, U.S. Govt. Printing Office, 1984.
[7] R. W. Zappe, Valve Selection Handbook. New York: Jaico, 1995.
[8] “Control valve capacity test procedure,” Amer. Nat. Stand. ANSI/ISA-S
75.02-1982, Instrument Soc. Amer.
M. A. Atmanand, photograph and biography not available at the time of
publication.
M. S. Konnur, photograph and biography not available at the time of
publication.