CHAPTER 3

Control Valve
 Definition: A valve or final control element used to control conditions (e.g.
pressure, flow, temperature or level) by fully or partially opening or closing in
response to the signals received by controllers.
 Functions:
 Maintain process variable (e.g. pressure, flow, temperature or level) at
their desired value, despite changes in process load.
Control Valve
 Flow characteristic
 The plug shape (trim shape) determines the flow characteristics.
 Three types of flow characteristics:
 Quick opening
 Linear
 Equal percentage

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 Quick opening
 Provides the maximum change in flow rate at early in the opening travel of the valve.
 The curve is basically linear through the first 40% and flattens out to indicate little
increase in flow rate as travel approaches the wide open position.
Applications:
 Used for on/off applications where significant flow rate must be established quickly as
the valves begins to open.
 Used in relief valve applications.
 Linear
 Flow rate is directly proportional to the valve travel.
Applications:
 For liquid level control where pressure drop is almost constant.
 Used for recycle pressure controls on compressors.
 Equal percentage
 Equal increments of valve travel produce equal percentage changes in the existing
flow.
 The change in flow rate (ΔF) is always proportional to the flow rate (If flow rate is
small, the change in flow rate will be small & vice versa)
 Most commonly chosen because it compensates for decreasing pressure differentials
as flow rate increases.
 It gives relatively small increments in Cv for the first 50%.
Applications:
 Used for pressure control applications
 Characteristic
recommendations
 Characteristic
recommendations
 Characteristic
recommendations
Type of valve
 Globe valve
 The valve stem moves a globe plug relative to the valve seat.
 When the valve is open, resulting in a relatively high pressure drop, limited flow
capacity and low recovery.
Advantages:
 Efficient and precise throttling
 Accurate flow control
 Suitable for high pressure & temperature
Disadvantages:
 Low recovery & low Cv
 High pressure drop, high pump capacity
 Not suitable for slurries
 Globe valve
Three patterns:
 Angle pattern
 Straight pattern
 Three-way pattern (Converging & Diverging)
 Globe valve
Straight pattern can be categorized into two types in terms of the number of plugs:
 Single-seated valve
 Double-seated valve

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/watch?v=bCsD4VUTnvc
 Butterfly valve
 Consists of a cylindrical body with a disk the same size as the internal diameter of the
valve body, mounted on a shaft that rotates perpendicular to the axis of the body.
 The disk pivots to the vertical position to shut off flow & horizontal position when fully
open.
 Used for throttling services.
Advantages:
 Offer high flow capacity at low cost
 Simple design, easy to install
Disadvantages:
 Have limited pressure range
 Not suitable for slurries
https://www.youtube.com/watch?v=zhi7_YQZhOs
 Ball valve
 Named from the valve plug segment being a ball or sphere that rotates on an
axis perpendicular to the flowstream.
 Fully open to fully closed is performed by a 90 degree rotation of the plug
segment.
Advantages:
 Suitable for slurries & liquids with solid matter because of its self-cleaning
operation
 Simple design
 Have greater capacity
 Have tight turnoff characteristics
 Lower cost
https://www.yout
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 Weir-type diaphragm valve
 Closed or open can be done by controlling the top flexible membrane
Advantages:
 Low cost
 Suitable for slurries & liquids with suspended solids
Disadvantages:
 High maintenance
 Poor flow characteristics

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 Eccentric rotary plug valve
 Combine the features of sliding-stem & rotary & use rotary actuator.
Advantages:
 Medium cost
 Require less closing force
 Used for forward or reverse flow
 Have high capacity
 Good shutoff characteristics
 Low wear
 Suitable for corrosive liquids

https://www.youtube.com https://www.youtube.co
/watch?v=qrEbzCAvhiM m/watch?v=xVrNx-nrZA4
Parts of control valve
 Control Valve Action
 Fail-Closed: A condition wherein the valve closure member moves to a closed
position when the actuating energy source fails.
 Fail-Open: A condition wherein the valve closure member moves to an open position
when the actuating energy source fails.
 Fail-Safe: A characteristic of a valve and its actuator, which upon loss of actuating
energy supply, will cause a valve closure member to be fully closed, fully open, or
remain in the last position, whichever position is defined as necessary to protect the
process. Fail-safe action can involve the use of auxiliary controls connected to the
actuator.
 Actuators
 Used to control various types of valves.
Requirements:
 Must be able to operate the valve against the pressure of the liquid acting on the valve.
 Must be able to tightly close the valve.
Other functions:
 Move the valve ball, plug or stem to the required position.
 Hold the position against the forces of the flowstream.
 Close off the flow by applying sufficient force.
 Provide the required operation for full control, from fully open to fully closed.
 Operate the movement at the required speed.
Types:
 Spring & diaphragm actuator
 Pneumatic piston actuator
 Electric motor actuator
 Electrohydraulic actuator

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=PsZOtcdVG6o
 Spring & Diaphragm Actuators
 Most popular & widely used.
Advantages:
 Simple, low cost, high reliability (have few moving parts)
 Suitable for throttling service
 Simple maintenance required
 Fail safe operation (full shut-off in the event that the pneumatic air supply fails)
Disadvantages:
 Relatively limited capability
 Not suitable for high force requirements
 Actuator force must work against spring.

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Spring & Diaphragm Actuators
 Fig. 13.13 (a): Reverse action for lifting a valve against the pressure of liquid on
the valve
 Fig. 13.13 (b): Direct action for moving a valve downwards against the pressure
on the valve.

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Spring & Diaphragm Actuators
Spring & Diaphragm Actuators
 A typical spring/diaphragm pneumatic actuator connected to a flow control
valve in action.
 The PLC analog output card produces a 4 to 20 mA current to move the valve
from fully open to fully closed.
 A signal conditioner called a current-to-pressure transducer or I/P will change
the 4 to 20 mA into 3 to 15 psi.
 Pneumatic Piston Actuators
 Second most popular.
Advantages:
 More compact and provide higher torque
 Suitable for throttling service
Disadvantages:
 High supply pressure required
 The requirement for positioner when used for throttling service
 Lack of inherent failure-mode system

https://www.youtube.com/
watch?v=MHlnTQV1Tn0
Pneumatic Piston Actuators
 Electric Actuators
 Consist of motors and gear trains.
 One very important consideration in choosing an electric actuator is its capability for
continuous closed-loop control.
Advantages:
 Economical for applications in small size ranges
 Resistant to valve forces due to stiffness (resulting in good throttling control for high
pressure valve)
Disadvantages:
 Larger units operate slowly & more costly
Electric Actuators

https://www.youtube.com/watch?v=NLscbeoIjAY
 Electrohydraulic Actuators
 Are electric actuator in which motors pump oil at high pressure to a piston, creating
the output force.
Advantages:
 Excellent choice for throttling because of its high stiffness
 Compatibility with analog signal
 Excellent frequency response and positioning accuracy
 Capable of very high output
Disadvantages:
 High initial cost
 Complex
 High maintenance

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/watch?v=q90WsygfACU
Comparison of Actuators
 Positioner (Position valve)
Functions:
 To linearize the control valve plug position with a control signal.
 Help to improve control by accurately positioning a control valve actuator in response
to a control signal.
 Used to feedback position information and ensure that the valve is in the correct
position regardless of the opposing forces.
 Positioners receive an input signal & provide output power to an actuator to ensure
valve positioning.
 The performance is depending on the accuracy of the position feedback and linkage
used.

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https://www.youtube.co
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 Plug
 Essential to use the force of fluid flow.
 To determine the flow characteristic (e.g. quick opening, linear, equal percentage)
 Limit switches
 These switches can either be a mechanical device or a proximity switch.
 Limit switches can send a confirmation signal to a PLC (Programmable Logic
Controller) or a DCS (Distributed Control System) to let the computers know if the
valve is open or closed.
 Have a visual beacon that is on top of the device to allow operators to visually and
easily see of the valve is open or closed.
 Stem
 Connects the actuator and disk
 Responsible for positioning the disk.
 Require sealing to prevent leakage.
 Two types:
 Rising stem: the stem will rise above the actuator as the valve is opened.
 Non-rising stem: No upward movement from outside the valve.
 Selection
 Factors that determine the choice of control valve type:
i. Type of liquid, gas, vapour
ii. Pressure & Temperature
iii. Flow characteristics
iv. Valve material
v. Operation frequency
vi. Connection type
vii. Fluid containing solids
viii. Corrosion resistance
Application of control valve
 Burner Station – control valve is used to control the fire combustion chamber
according to set point (SP).
 Application of control valve
 Control valve is used to control pressure from PT tank and PT from compressor.
Application of control valve
 Control valve is used to control pressure from PT tank for vapor outlet