CHAPTER 1

CLASSIFICATION OF VALVES

1.1 INTRODUCTION

Efficient and economic running of any process plant depends on the efficiency of
the control element in responding to regulating (control) requirements or isolating
requirements of the process .One such control element is the valve. Isolating valve is
used for on/off purpose. A control valve is always a pressure-reducing device. A valve is
either automatic or manual operated device for controlling the process fluids like liquid,
gas, corrosive chemicals, slurries, liquid metals, and radio active materials etc through
pipes. Valves usually allow movement of fluid in one direction.Control valves must be
selected taking into consideration the control purpose, process conditions, pipe sizes and
all other related factors. It is very important to select an optimum size for the control
valve, which is the final control element in a control loop. If the final control element is not
of proper size for a particular process application, or if the selected valve does not
function as planned, the total effort goes in vain.

A control valve may have pneumatic, hydraulic, electric or other externally

powered actuator that automatically positions the valve plug as dictated by the signal
transmitted from the controller. These signals may be derived from process variables
such as pressure, temperature, flow, and level. Control valves are used primarily to
throttle energy in a fluid stream and not for shut off purpose. Due to this the control valve
body assembly is considerably different from the shut-off valve. Valves may operate at
pressures in the vacuum region to pressures of 6000kg /cm 2 or more, temperatures from
cryogenic region to those of molten metals.

The sizing of a valve is a part of valve selection. Sizing is accorded more

importance because the very function of the valve selection proceeds depends on the
accuracy of sizing. Optimum sizing of a valve will give the correct controllability and better
performance of the system. On the other hand using a higher size valve will abnormally
increase the cost.

1.2 CLASSIFICATION OF VALVES

Valves can be classified according to nature of the closure members employed.

Almost all valves will fall into one of the fallowing basic eight categories

1
1.2.1 BALL VALVE

It is basically a ported sphere inside the housing. Rotation of the sphere by 90 0

changes the position from open to close.Ball valves are used in a wide range of
applications including flow control, pressure control and shut-off. These valves generally
have a very low pressure drop and low leakage.The seat of the ball valve is subject to
extrusion in throttling applications.

1.2.2 BUTTERFLY VALVE

It consists of a disc which rotates about a shaft in the housing, and close against
a ring seal (seat) to shut off the flow.These are generally used in large diameter lines and
in systems where leakage is relatively unimportant,viz. pen stocks of hydro-stations,
C.W. lines in thermal stations. These valves require high actuation force.

1.2.3 GATE VALVE

It is characterized by a sliding disc or gate, which is moved by the actuator

perpendicular to the direction of flow. These are used primarily as stop valves. I.e. fully
open or fully closed . Gate valves have slow response characteristics and require large
actuating force.

1.2.4. GLOBE VALVE

There are three types of valves in the globe family,viz. globe, angle and Y type.
The closure member, usually a disc or a plug is moved by an actuator stem
perpendicular to a ring shaped seat. Primarily it is a general-purpose flow control valve .It
is faster in opening and closing than the gate valve. Globe valves are often heavier than
other valves of the same flow rating.

1.2.5 PINCH VALVE

These valves are characterized by one or more flexible elements such as

diaphragms, rubber tubes, which can be moved together to press against a stop to pinch
off the flow. These valves are used in systems carrying slurries, gel etc. It is relatively low
cost, has low-pressure drop and can be tightly closed. Flexible members are subjected to
wear and require periodical replacement.

1.2.6 POPET VALVE

Mainly used in pressure control, safety and relief functions. Has excellent leakage
control, and low pressure drop.

2
1.2.7 TAPPER PLUG VALVE

Similar to ball valve except that the closure member is a tapered plug instead of a
ball and there is no through port in the plug. These are useful in high temperature, low-
pressure applications. These are not usually suited for steam services.

1.2.8 SWING VALVE

Primarily used as check Valves to block flow in one direction.It suffers from high
leakage and is subjected to contamination build upon the closure member and in the
clearances.
Further depending on their construction the valves can also be classified as sliding
stem or rotary type.

1.3 VALVE SELECTION PARAMETERS

The Valves are selected mainly considering the following parameters.

A. Type: Single seated, double seated (Figs No. 1.1 to 1.3), Sliding stem type,
Rotary type, Angle type (Figs 1.4 to 1.6) etc.

B. Size: Capacity to handle the flow rate.

C. End connection type: Flanged, Screwed, Welded, etc.

D. Pressure Rating: Determined by the Temperature and Pressure of the

medium.

E. Capacity: Cv Value determined by designed flow rate.

F. Flow Characteristics: Equal percentage, Linear, Quick opening, etc.

G. Plug Type: Contour, ‘V’ ported, Soft seated Tight Shut-off, etc.

H. Actuator: The valve plug, Stem and the Valve Body have to be designed to
with stand the thrust of the Actuator.

I. Materials of the Body & Trim: This depends on the nature of the fluid
handled. Body material is normally C.I., C.S., CSS or other special alloys
suited to the fluid handled. For high Temperature applications the body is
made of creep resistant alloy steel containing chromium and Molybdenum.
Trim (internal parts) is made of corrosion resistant stainless steel. In order to
withstand wire drawing and erosion the valve plug and seat rings are
hardened with stellite.

3
 FIG: 1.1

Model :VDN
Double Seated Low Noise Valve
(Rating : ANSI 600 or Less )

Double seated low noise valves are featured with very low operating noise
(aerodynamic noise) when they are used to handle compressible fluids (such as steam,
air, natural gas, and ethylene gas). These valves operate still more silently than VDC
cage valves.
The cage and valve plugs are of a multiple hole construction. The components for
“restriction, divergence” and “expansion” are laid out in a rational manner to accomplish
low noise pressure reducing action. Components are interchangeable with those of the
VDC cage type valves.

FIG : 1.2
Model :VDN
Double Seated High Pressure
Low Noise Valve
(Rating : ANSI 900 - 2500 )

Double seated high pressure low noise valves are featured with very low operating noise for
higher pressure rating of ANSI 900-2500 when they are used to handle compressible fluids
(such as steam, air, natural gas, ethylene gas and etc.). Components are interchangeable
with those of the VDC high-pressure cage valve.
4
 FIG: 1.3

VDC: Double seated cage valve.

Rating: ANSI 600 Or less

Double seated cage valves can be used for general applications as top and bottom
guiding double seated valves. However, balanced holes in the plug can eliminate the
unbalanced thrust in great efficiency and provide dependable operation against
vibration and attrition with flashing fluids or at high pressure differentials. The valves
can provide bubble-tight shut-off with the seat. The body is constructed for simpler
disassemble, faster checking and easier part replacement. Also, the change of flow

Fig:1.4
Model :VAV
Venturi Throat Type
Angle Valve

Venturi throat type angle valves are used for directing horizontally flowing fluid to the
downward direction. It is particularly used for slurries and viscous or flashing mediums.

5
 FIG: 1. 5
Model :VAC
Cage Type High
Pressure Angle Valve

These are cage type angle valves with forged body suitable for high-pressure
service. The valve plug is provided with balancing holes so that the unbalanced
thrust caused by fluid can be reduced. The unit can be made in large sizes, and
affords dependable operation at high pressure or high-pressure differentials.

FIG:1.6

Model :VAC
Cage Type Angle Valve

In cage type angle valves, the plug is provided with balancing holes so that the
unbalanced thrust caused by fluid will efficiently cancel out each other. The design
affords dependable operation at high-pressure differentials without requiring a
large actuator. The valve plug is housed entirely in the cage, and strongly resistant
to vibration and wear.

6
Table 1.1 Valve selection guide

Ball B’fly Gate Globe Pinc Plug Poppet Swing

Check Valve P P P P h
P P G G
Contamination Free G F G G G G F P
Corrosive Fluids G P P G P P G P
Hydrogenic Fluids G P P G P P G P
Gasses G G G G G G G G
High P P P F G P F F P
High Flow G G G G G G G G
High Pressure G P P G P P G P
High Temperature G G G G P P-G G G
Leaktight G P G G G G G P
Light Weight G G F P F G G G
Liquid G G G G G G G G
Low Actuation Force F P P P P P G G
Low Cost G F-G G F-G S G G G
Low P G G G P G G G G
Low Flow Control G G P G P G G G
Rapid Opening G G P F-P G G G
Relief P P P P P P G P
safety valve P P P P P P G P
Seat Erosion
F P P G P F F-C P
resistance
Slurries F-G P P P G P P F
Smal physical size G G P P P G G G
Steam service G P P-F G P P G P
Tarqiling P P P G F-P P G P
Vibration free F P P G G G P P

P= poor. Not recommended F = fair, Better choice available

G = good, Recommended for use under normal conditions.

7
 CHAPTER 2

CONTROL VALVE SELECTION AND APPLICATION

2.0 INTRODUCTION

Valve selection depends upon the function the valve has to perform after it has
been installed, the properties and working conditions of the working fluid. The material of
the valve also depends on the working fluid. General valve functions can be On-Off
service, Throttling service, Prevention of reverse flow, Pressure control and special
functions that include Directional flow control, Sampling service, Limiting flows, Sealing
vessel and other miscellaneous functions.

2.1 FLUID PROPERTIES

Specific gravity, viscosity, corrosiveness and abrasiveness etc. of liquid / gas /

slurry handled through the valve should be known. An analysis of the system should be
made, to determine passage of more than one fluid through the valve.

2.1.1 FLUID FRICTION LOSSES

Various types of valve exhibit varying degree of pressure drops due to friction to
the flowing medium. A system requirement of permissible pressure drop must be taken
into consideration during valve selection.

2.1.2 FLUID PROPERTIES AND VALVE MATERIAL

The valve material selection is directly related to the fluid properties of

corrosiveness and abrasiveness. The combination of operating pressure and temperature
will also influence in determining the permissible materials of construction.
.
2.2 OPERATION CONDITIONS

Establishment of actual operating conditions of each valve will simplify valve

selection procedure. One normally encounters the following while selecting the Control
Valves for different applications.

a. Leakage
b. Rangeability
c. Cavitations
d. Noise, Vibration & Flow Velocity
e. High Pressure
f. High Temperature
g. Low Temperature

8
h. Low Flow
i. Viscous and slurry streams

2.2.1 LEAKAGE

Any flow through a fully closed control Valve when exposed to the operating
pressure differentials and temperatures is referred to as Leakage. It is expressed as a
cumulative quantity over a specified time period for shut off designs and as a percentage
of full capacity for conventional control valves. (Refer American national standard control
valve seat leakage Appendix-1).

2.2.2 FACTORS EFFECTING LEAKAGE

Normally the valve co-efficient (leakage) is applicable to fully closed valve. This
figure applies only to the new valves or valves operating at ambient temperatures with
clean working fluids. After a few years of service valve leaks vary drastically as effected
by the factors such as erosion of seat materials and due seating forces, fluids carrying
abrasive particles, temperature variations, pipe line forces.

The general experience is that either the valve body is at a different temperature
than the trim or the thermal expansion factor for the valve plug is different from the
expansion factor for the body material. In such cases it is usual practice to provide
additional clearance to accommodate the expansion of the trim, when designing a valve
for hot fluid services. If this valve is operated at low temperatures the leakage will be
higher.

Temperature gradient across the valve can also generate strains that promote
leakages. eg: three way valves used for combining services where the two fluids
involved are at different temperatures.

Strain thrusted on control valves by pipes will lead to leakage. Hence, sufficient
supports to pipe line should be provided such that the control valve will not be loaded
with excessive bolting strain when connecting it or placing it in the pipeline.

Seating materials are selected for compatibility with service conditions and stellite
or hardened stainless steel is an appropriate choice for non-lubricating, abrasive, high-
temperature and high pressure drop services. These hard surface materials increase the
life of valves by reducing the risks or cuts occurring on the seating surfaces.

2.2.3 RANGEBILITY

Rangebility of a control valve is defined as the ratio between the maximum

&minimum flows within the limits of the inherent flow Characteristics of the Control Valve.
The rangebility of a regular cage type and contoured type Trim is 30:1.

a. It tells the points at which the valve is expected to act on off or lose control completely.

9
b. It establishes the points at which the flow – lift characteristics starts to deviate from the
expected.

2.2.4 NOISE

The noise is generated by the passage of process fluids through the interior of the
valve. Three main types of noise occur due to mechanical vibration, cavitation and
aerodynamics. Each can be avoided or alleviated but the methods are very expensive.

2.3 VALVES FOR HIGH PRESSURE AND TEMPERATURE

Control Valve for high pressure and high temperature applications require special
selection of materials and design to ensure long and trouble free service.

2.3.1 VALVE BODY

Materials chosen for the valve body should have enough tensile yield and creep
resistance to withstand high temperature. Alloy castings as per ASTM A217 are usually
specified for body components of valves handling steam and other non-corrosive fluids at
temperature between 400 to 500 0 C. These alloys meet the pressure and temperature
ratings listed under carbon-moly and chrome-moly steels of ANSI B 16.5. , Grade WC1, a
carbon moly alloy and grade C 5, a chrome-moly alloy are the most commonly used.
Grade C 5 is often used on valve bodies handling steam condensate and boiler feed
water in power plants even though the pressure and temperatures are low. Molybdenum
provides creep strength at high temperatures and chromium adds to corrosion resistance
and strength. All these steels are of welding quality and should be annealed after
welding. Chrome-moly alloys have higher hardness, which helps to withstand flashing
and cavitation of high-pressure liquids like feed water.

The end connection used for high temperature valve is butt-welding. Welded
connection avoids leakages through flanged joints subjected to thermal cycling.

2.3.2 BONNET

Bonnet materials are same as that of valve body materials. For temperature
above 2000 C, an extension bonnet with radiating fins is used. Where this construction is
not practical special high temperature packings are used. Braided asbestos with inconel
wire reinforcement and lubricated with graphite permits operation up to 540 0 C. Graphoil
a new form of solid carbon packings may be employed at temperatures of 800 0 C and
above.

2.3.3 BOLTS

The bolting used on Cast steel and alloy steel bodies is generally as per ASTM A
193.The grade commonly used up to 450 0C is B7 and B14 for higher temperatures. Nuts
used on studs are generally as per ASTM A 194, grade 2H for temperatures up to 450°C
and grade 4 or 8 for higher temperatures.

10
2.3.4 TRIMS FOR HIGH PRESSURE DROP

Flashing and cavitations occurs under high-pressure drop of liquids as in the case
of feed water valve. It further causes hydrodynamic noise. To avoid this, the trim is so
designed that the pressure drop is made to occur in steps. The pressure drop at each
stage is so designed that the pressure of the liquid does not drop below the saturated
vapour pressure at the Temperature.

11
 CHAPTER 3

CONTROL VALVE FLOW COEFFICIENT

3.0 INTRODUCTION

Once the type of valve is chosen for an application the next step is to determine
correct size. Control valve sizing will give the optimum port size for better controllability
and performance of the system. Using higher size will abnormally increase the cost and
lower size will not meet the requirements of the process. Also, based on discriminating
analysis of past experience it is necessary to get correct data for arriving at correct sizing
of a valve. For example, if it is assumed that the flow is large but the pressure drop
across the valve is excessively low then both these factors lead to a larger valve size.
This will result in higher investment, hence the actual flow rate and pressure must be
known to arrive at correct size.

3.1 VALVE COEFFICIENT / FLOW COEFFICIENT OF VALVES (Cv)

Cv is actually a means of knowing the relative capacity of each size of valve. By

definition it is “the number of GPM of water at 60° F that will pass through the valve with a
pressure differential of 1 psi”.

Cv for liquids (Water)

Cv = V G/DP
OR
V = Cv DP/G
OR
DP = G ( V / Cv) 2

Where Cv : Flow coefficient of valve

DP: Pressure drop (psi) at maximum flow
G : specific gravity at fluid temperature
V : flow volume (U.S.g.p.m) at fluid temperature

Different valve designs will have different Cv. The numerical example is worked out below
for evaluation of Cv.

Example
Calculate the Cv value for the following conditions,
Maximum flow = 600 g.p.m. Fluid
Temperature = 500°F
Specific gravity = 0.7 at 500° F
Pressure drop = 70 psi
Cv = V G/DP
= 600 x  0.7 / 70
= 60

12
3.2 DETAILS REQUIRED FOR SIZING OF VALVE

The following information are required for optimum sizing of the valve.

i) Flow application data

a) Flow rate : Maximum, minimum & normal

b) Pressure : Upstream, downstream at maximum, minimum and
Normal flow.
c) Temperature : Of the fluid

ii) Fluid data

a) Name of the fluid

b) Fluid phase : liquid, gas, or slurry etc.
c) Density, specific gravity, specific weight, molecular weight etc.
d) Viscosity (Liq)
e) Vapour pressure (Liq)

iii) Piping influence:

Presence of reducers or other disturbances at the valve which will change the
rated capacity.

iv) Valve selection information.

a) Range ability
b) Corrosion & erosion resistance.
c) Special requirement (tight shut off, low noise etc)

v) Sizing calculation

Manufacture`s sizing co-efficient, sizing formulas, monographs etc.

3.3 VISCOSITY CORRECTION

Viscosity represents a factor of flow resistance of a fluid. One can experience a

well-known fact that water flows out of a bottle rapidly than honey, at the same
temperature. The reason is viscosity of honey. If water and honey are allowed to pass
through same type of valve with same temperature and with same pressure, more water
flows out than honey in the given time. For the same quantities of water and honey to
flow out of the valve in the same period, the valve opening for honey flow must be made
larger, than that of water flow.

13
 No viscosity correction is required for a fluid having viscosity less than 100 ssu
(saybolt second universal). In other cases, viscosity correction should be made to get
reliable results /flow. Steps for calculation of viscosity factor are given below.

1. Calculate the Cv value as mentioned in example of section 3.1 using flow and
pressure drop.

2. Calculate viscosity factor R by using equation B for process fluid having viscosity
more than 200 ssu or equation A if the viscosity is less than 200 ssu after converting
the unit into cs (centistokes)

cs =( (0.22) (ssu) – 180/ssu))

Equation A: factor R = (10,000) (v) /  Cv x cs

Equation B: factor R=(46,500)(v)/ Cv x  ssu
where , v: flow volume (g.p.m)
ssu : viscosity (say bolt seconds universal )
cs: viscosity (centistokes)

3. On the viscosity correction curve (Fig3.1), read the correction factor at intersection
point of factor R

4. Multiply the Cv value calculated in step (I) by the correction factor.

5. Use this corrected Cv to select the valve type / size from the published Cv data.

Example

Calculation of Cv value when maximum flow, specific gravity at operating

temperature, pressure differential across the ports and viscosity of fluid are known.

Conditions of process:

Maximum flow = 42g.p.m (100° F)

Fluid temperature =100° F

Specific gravity = 0.95 (at 100° F)

Pressure differential = 5 psi

Viscosity = 2800 ssu (100°F)

Cv = v g/p = 420.95/5 = 18

14
 Cv Correction factor
VISCOSITY CORRECTION FACTOR
Fig 3.1

Cv after applying viscosity correction is as below

1. Cv = v g/p = 42 0.95/5 = 18(approx)

2. Since the viscosity is greater than 200 ssu,calculate factor using equation B

Factor R = 46,500 X 42 = 163 (approx)

√18 x 2800

3. from the correction curve (fig) the Cv correction factor to be 1.30

4. The corrected Cv value is calculated to be 18 x 1.30 = 23.4

From the Cv value a valve can be chosen by matching the calculated Cv to that of the
manufacturer’s Cv verses port size chart for different valves. This may result in more than
one type, which may have to be restricted by selecting suitable type of valve for particular
application as Table 1.1

3.3 FLASHING OF LIQUID

The state of fluid depends on its temperature and pressure. When the temperature
is below the boiling point, the fluid is in the liquid state. When the temperature is higher

15
than the boiling point, the fluid is in the gas state. The boiling point, is a function of the
pressure, as the pressure is higher, the boiling point is higher.

In certain applications the fluid enters the valve inlet, in liquid state, and flows out
as a mixture of gas and liquid or in gaseous state. This indicates that the fluid while
passing through the control valve changes its state partially or fully to a gaseous state
between inlet and out let of the control valve. In this circumstance, a problem of whether
the fluid is to be regarded as liquid or as a gas for valve sizing arises.

It is impracticable to accurately measure flashing, and reliable formulae for valve

sizing for flashing fluids are not available. In such cases the formula for flashing water
described below gives a closer solution. When hot water at or near saturation
temperature flows through a control valve with, pressure reduction, thermo dynamic
consideration indicates that a mixture of water and steam will exist at the outlet of the
valve.

For determining Cv value and valve sizing in such cases, the allowable pressure
drop is calculated, result is compared with the desired pressure drop, and smaller of the
two is used as P in flashing liquid equation.

1. The allowable pressure drop, when the in let temperature is lower than the
saturation temperature by 5°F or over, is determined as shown.

Allowable pressure drop = 0.9 (P1- Ps)

Where, P1 = Inlet pressure (Psia)

Ps = Saturation pressure (Psia) corresponding to
inlet temperature

EXAMPLE
Calculate the Cv value known conditions are:

Inlet temperature = 330° F

Inlet pressure = 165 Pisa

Outlet pressure = 95 Pisa

Pressure drop = 70 Pisa

Maximum flow = 350 g.p.m water

Solving the for Cv

1. Pl = 165 psia (saturation temperature = 366°F)
Ps = 103 psia (saturation pressure corresponding to inlet temperature
33 0°F
2. The inlet temperature (330°F) is lower than the saturation temperature by
36°F.

16
 3. Allowable pressure drop =0.9(165-103)=55.8 Psi.
4. Since allowable pressure drop is lower than the desired pressure drop
therefore, this figure is used for Cv calculation in this case. Cv =46.8.

When the inlet temperature is lower than the saturation temperature by 5°F
or less, the equation given below is used to determine the allowable pressure drop

Allowable pressure drop = 0.06 P1

Where P1 = pressure (Psia) at inlet

EXAMPLE
Calculate Cv value known conditions is.

Maximum flow = 70g.p.m. water

Inlet temperature = 340°F
Inlet pressure = 120 Psia
Pressure drop = 30 Psia

Solving for Cv

1. P1=120 Psia (saturation temperature=341°F)

2. The inlet temperature is lower than saturation temperature by 1°F.
3. Allowable pressure drop = 0.06 x 120=7.2psi
4. This pressure drop figure is lower than the actual pressure drop
(30 psi) and, therefore, this figure is used for calculation.
5. Solving the equation (for liquid) for Cv, Cv = 26

3.4 LIQUIDS OTHER THAN FLASHING WATER

As mentioned earlier, accurate measuring methods of flashing water are not

available, therefore empirical methods are used for sizing of valve. A method often used
for flashing liquids other than water involves a) flashing degree is estimated b) C v values
for liquid and gas are separately calculated and c) the two C v values are added to obtain
the required Cv value. This method results in a large Cv and valve size becomes slightly
larger than actually required. In this method it is assumed that steam or gas existed
already when the liquid entered the valve and that the flow speed of steam or gas is
same as that of liquid.

EXAMPLE
Fluid ammonia
Maximum flow 100 g.p.m
Flashing rate 10%
Fluid temperature 83° F
Pressure drop 50psi
Inlet pressure 150psig.
Outlet pressure 100psig.
Specific gravity (gas) 0.596
Specific gravity (liquid) 0.89

17
Solving for Cv

1. Estimate the liquid and gas flow volumes of the valve.

(a) 90% of 100 g.p.m = 90 g.p.m of liquid.

(b) 10% of 100 g.p.m=10 g.p.m of gas.
As converted into scfh 10g.p.m of gas =97.810 scfh

2. Calculate the Cv value for liquid

3. Calculate the Cv value of gas by the formula

Q = quantity of gas in standard cubic feet /hour at 14.7psia and 60OF

G = specific gravity at 60 deg. F

Ta = Absolute temperature (460+ OF)
P = Pressure drop
P1= Inlet pressure(Psia) at maximum flow
P2 = Out let pressure(Psia) at maximum flow

4. Addition of the above two values gives the Cv value

12.00+15.22=27.22

3.5 VALVE SIZING FOR GASES

Gas is a compressible fluid and its density depends up on pressure. As the gas
flows through the control valve, its density varies as its pressure falls. All formulae for
valve sizing for gasses assume average densities. Valve size becomes smaller if the
upstream density is used, it becomes larger if the downstream density is used. The
density cannot be ascertained accurately. It is assumed that the gas is of ideal nature
and the relationship between pressure and density is linear. The formulae are based on
an assumed density of average pressure, which is (P1+P2) / 2.The assumption has been
proved to be effective through actual application tests.

Equation 1

18
When the pressure drop is less than a half of the inlet pressure ( inlet absolute pressure )

Equation 2
When the pressure drop is equal to or more than a half of the inlet absolute pressure
:

Where: Cv : Flow coefficient of valve

G : Specific gravity at 60 0 F(air = 1.0)
P1 : Inlet pressure(psia) at maximum flow.
P2 : Out let pressure(psia) at maximum flow.
P : Pressure drop (psi) at maximum flow.
Q : Flow ( ft 3 / hr ) at 14.7 psia ,60 0 F
Ta : Absolute temperature (460+ 0F)

EXAMPLE

Maximum flow = 1,500,000 scfh.

Pressure drop = 40 psi.
Specific gravity = 0.6 (at 60 0F).
Inlet pressure = 140 psig.
Outlet pressure = 100 psig.
Inlet temperature = 200 0F.

Since ΔP is smaller than a half of P1 (inlet absolute pressure) equation 1 is used.

EXAMPLE

Calculate the Cv value . known conditions are:

Maximum flow = 105 scfh.
Pressure drop = 800 psi
Specific gravity = 1.0 at 600F.
Inlet pressure = 103 psig.
Outlet pressure = 200 psig.
Fluid temperature = 2200F.

Since ΔΡ is greater than a half of P1, equation 2 is used.

19
3.6 STEAM

Valve sizing for steam applications, the formulae is derived from liquid formulae
employing appropriate unit conversion factors. Formulae are developed on assumption
that steam follows the law of the ideal gas. Errors encountered in this method of valve
sizing for steam applications are found to be negligible.

1. When the pressure drop is less than a half of the absolute inlet pressure

2. When the pressure drop is the same or more than half of the absolute inlet
pressure

Where:
W = lbs/hr
P1 = inlet pressure (psia)
P2 = Outlet pressure (psia)
Cv = flow coefficient of valve.
S = super heating

EXAMPLE
Maximum flow = 45x103 lbs/hr
Outlet pressure = 250 psig.
Inlet pressure = 380 psig.
Pressure drop = 130 psi.
Superheating = 2000F.

Since ΔΡ is smaller than a half of P1 equation 1 is used.

Example
Calculate the Cv value. Known conditions are
Maximum flow = 6 x 103 lbs/hr
Inlet pressure = 100 psig.
Outlet pressure = 20 psig.
Pressure drop = 80 psi.
Superheating =3

20
3.7 CONVERSION OF Cv FORMULA

In this section the formulas for computation of Cv in metric units are given.

FOR LIQUIDS

WHERE
V = Maximum flow, m3/hr.
G = Specific gravity.( water =1)
P1= Inlet pressure, kg/cm2
P2 = Outlet pressure, kg/cm2.

3.7.1 VISCOSITY CORRECTION FORMULAE

1. First solve for the Cv, assuming no viscosity effect.

2. Solve for factor R from equations, A` or ,B` for viscosity in centi stokes / ssu .).

V : Maximum flow,m3/hr
Mcs : Centistoke at flowing temperature
Cv : Cv value uncorrected for viscosity.
Mssu :SSU at flowing temperature
Eq A` valid for viscosity < 200 SSU
Eq B` valid for viscosity > 200 SSU.

3. Intercept of factor R with the viscosity curve gives the correction factor.
4. Multiply Cv by the correction factor of step 3.
5. Use this corrected Cv to select the valve size from the metric Cv table .

FOR GASES

1. The following formula shall be used for calculation with no corrections when the
maximum flow is given at the standard conditions ( 760 mmHg and 15.60C)

When ΔΡ < P1 / 2

21
When

Q : Max. flow (m3 /hr) at 760 mmHg, 15.60C

G : Specific gravity(air = 1)
tf :Fluid temperature( 0C )
P1 : Absolute inlet pressure (Kg/cm2 abs) at maximum flow.
P2 : Absolute outlet pressure(kg/cm2 abs) at maximum flow
ΔΡ = Pı - P2 (kg/cm2)

FOR STEAM

For the case ∆ P = ≥ P1 / 2

W : Maximum flow(kg /hr)

P1 :Absolute inlet pressure(kg/hr abs)
P2 :Absolute outlet pressure(kg/cm2 abs)
ΔΡ = Pı - P2 (kg/cm2)
(NOTE: P1 and P2 denote the pressure at maximum flow.)
K: 1 + (0.0013 x superheat0 C)

FOR VAPORS

22
 When P2 < ½ P1, use p1/2 in place of ΔP, V2 used must be that corresponding to P1/2
W : Maximum flow (kg/hr)
V1 : specific volume (cm3 / gr at P1)
V2 : specific volume (cm3 / gr at P2)
P1 : Absolute inlet pressure (kg / cm2 abs.)
P2 : Absolute outlet pressure (kg / cm2abs.)
ΔP : P1 - P2 (kg/cm2)
P1 and p2 denote the pressure at maximum flow.

Note

Kv VALUE: wherever the valve capacity is expressed in Kv it denotes the

maximum flow rate of water through the valve in m3/ hr under a pressure
differential 1kg/cm2. The relation between Cv and Kv is given as Cv = 1.17 Kv.

3.8 BUTTERFLY VALVE Cv

Flow Co-efficient of butterfly valve for regulating and on of services are derived from the
below formulae.

1. Cv = 17D (for 60 % opening)

Cv - flow co-efficient, D - port diameter in inches (regulating service)

2. Cv = 27D (for 90% opening)(on-off service)

3.9 SPECIAL FEATURES OF BUTTERFLY VALES

1. Valve is specially meant for low-pressure drop application at low static head.

2. It is very economical because cost of metal required for valve body us very
less in comparison with globe type valve body.

3. Tight shut off is achieved by providing resilient sealing on the body or vane.

4. Whenever valves are used for high temperature service it is supplied with
metal searing having sear leakage, confirming to reputed internal standards.

5. Design is very compact.

6. Actuator torque required is very less in comparison with any other valve.

7. Valve is well balanced at fully closed condition.

8. Valve can be used for throttling service between 10-60 opening beyond this it
causes instability and no control.

23
 9. It reduces the pumping cost because pressure drop across the valve is very
less.

10. It has maximum flow capacity.

11. Space required for the valve is minimum on the pipeline.

12. Installation and handling is very easy.

Table 4 –Typical Cv values for different Valves and port sizes.

Port Three way valves Adjustable Port butterfly valves

size port valves size
VTM VTD VzA (mm.dia.) VBL VBS
ANSI 300lb VBM JIS
Or Lower VBH 10 Kg/cm2
JIS VBZ
10 Kg/cm2 ANSI 300,
600 lb

½ 80 160 160

¾ 6.3 100 280 260

1 10 125 450 410

1¼ - 150 610 580

1½ 23 200 1,040 960

24
2 40 100 250 1,700 1,550

2½ 63 130 300 2,480 2,250

3 90 70 140 350 3,300 3,000

4 160 130 250 400 4,350 4,000

5 250 200 420 450 5,500 5,000

6 360 270 570 500 6,800 6,200

8 640 480 1,000 550 8,200 7,400

10 1,000 750 1,600 600 9,800 9,000

12 1,440 1,080 650 11,400

700 13,300

750 15,300

800 17,300

900 21,900

1,000 27,000

CHAPTER 4

OTHER METHODS FOR VALVE SIZING

4.0 INTRODUCTION

Once the Cv of a valve is known, the amount of flow at a given pressure drop can
be found, conversely, the pressure drop can be determined for a specific flow. On the
other hand, for a specified flow and pressure drop, the flow coefficient can be computed
and the type and size of the valve to be used can be determined from published Cv data.
In this chapter various formulas for valve sizing and equivalent orifice method of valve
sizing is described.

4.1 DETERMINATION OF PROCESS PARAMETERS FOR VALVES

25
 Various parameters like differential pressure, flow of viscous fluids and selection of
suitable valve from published Cv data for 2” valve is dealt here by means of numerical
examples. The Cv values for 2” valves are given in Table 4.1 below.

TABLE 4.1 : TYPICAL Cv VALUES FOR 2 in. VALVE

TYPE Cv

Angle valve 64.0

Ball check valve 154.5
Ball valve (full port) 228
Ball valve (standard port) 120
Butterfly valve 145
Coaxial valve 154.5
Cone poppet check valve 166
Flat poppet check valve 133
Gate valve 210
Globe valve 44.34
Pinch valve 181
Plug tapper valve 70
Swing check valve 138.2
y-valve
45° angle 72.0
60° angle 70.2

EXAMPLE

To calculate the expected pressure drop in a 2 in. full port ball valve is to carry water
at a rate of 556 gpm.

From Table 4.1 Cv = 228, thus:

EXAMPLE

A 2-in. globe valve is allowed a pressure drop of 64 psi when carrying water. To
calculate the gallons/ minute of oil (specific gravity 0.8, kinematic viscosity 0.82) that will
pass through the valve and the expected pressure drop. The kinematic viscosity of water
is 0.93.

26
 From Table 4.1 Cv = 44.34, thus:

EXAMPLE

Determination of an appropriate type of 2 in- valve to carry 100 gpm of water with a
pressure drop of 1.98 psi across the valve.

From Table 4.1 it is seen that a 60° angle valve will meet the requirements.

Table 4.2 EQUATIONS FOR VALVE SIZING

Computation of Q – flow quantity in gpm.

Computation of deo – equivalent orifice
Computation of d - trail and error method of equivalent orifice.
Computation of W - lbs./hr

27
28
4.2 EQUIVALENT ORIFICE METHOD
Since the flow through a sharp edge orifice can be conveniently calculated with
good accuracy, it would be desirable to relate flow through a valve to that through a sharp
edge orifice. This can be done to high accuracy with the use of the equivalent orifice
method.
This procedure consists of three basic steps. The first step is to compute the sharp
edge orifice diameter. This can be found from one of the following equation (see Table
4.2 for alternate forms of equation) for liquids, depending on known quantities.

formula for gasses under sonic flow conditions.

The next step is to determine the equivalent orifice diameter from one of the
following equations depending on known quantities.

29
. If dEO can be computed, an adjustment is made in one or more parameters until
dEO is made equal to d. This can be done by changing d L for a value of known K or by
changing K to meet a required line size. If neither is known, K may be computed from

or

and the line size chosen to meet this K-factor. Alternatively, a new valve and K factor may
be chosen to fit a line size.

If dEO cannot be computed from known information, a trial and error

procedure can be used. Set dEO equal to d and use figs.4. 1 and 4.3 to choose a valve.
From its coefficient C and d EO find the proper line diameter, or conversely, from a required
line diameter find the valve type from the coefficient C. once the valve coefficient and line
diameter are known, the K-factor for the valve may be found from fig.4.2.
In summary, to fully size a valve for a given flow and pressure drop,
determine the coefficient C, the K-factor of the valve, and its line diameter. Note that one
or two, but not all of these may be specified before hand. All three may be specified if the
flow and/or pressure drops are not specified.

Example
A 1½ -in full port ball has a valve flow coefficient C of 1.7. The number of
gallons per minute of water it will pass with a pressure drop (p) of 1.2 psi is found as
follows.

From fig.4.3 for C = 1.70 ,dEO = 2.62 in . Hence

30
Valve flow coefficient C. The value for Valves is based on full ported design.
Fig 4.1

31
 Vlave Configuration C
Head Loss Fdactor K

HEAD LOSS FACTOR FOR VALVES

Fig 4.2

32

Inside diameter of line , d L (in) d Eo = C(dL)1.07)

Equipments orifice diameter ,dEO (In)

Valve flow coefficient C

BUTTERFLY VALVE Cv-
Inside Diameter dL ( in)

Inside diameter of line dL (in)

FIG 4.3

33
 CHAPTER 5

PLUGS AND THEIR CHARACTERISTICS

5.0 INTRODUCTION

A plug is a closure member of a valve. This part of the valve actually closes the
orifice to stop the flow. Depending on the shape of the plug different flow characteristics
can be obtained. Here three main contours viz. Equal percentage, linear, quick opening
normally encountered in process application are explained.

5.1 EQUAL PERCENTAGE CONTOUR PLUG

This is designed to give a constant rate of change of flow for unit change in lift,
i.e. equal increments of lift produces a ‘rate of change’ in flow which is proportional to the
amount flowing before the change occurred. It provides the necessary control
characteristic where control is required over a wide range and meets the majority of
installation requirements. Contours of 50:1 ratio are generally available. This plug is
usually employed in the following applications.

 Where the pressure drop across the valve is a small portion of the total e.g.
generally less than 40%.

 Where the pressure drop across the valve varies widely e.g. storage vessel run –
down or varying set point conditions.

 Where the required valve capacity is uncertain as it is more difficult to oversize a

valve for this characteristics.

 Where ever considerable lag exists in the system and for reasons when the rate or
derivative action is in the controller.

34
 Fig 5.1

5.2 LINEAR CONTOUR PLUG

In linear contour plug the flow characteristics are linear.the fluid flow is in direct
proportion to the valve lift. Equal increments of lift produces equal increments of flow
through out its range.

This is usually employed in the following applications

a) Where the pressure drop across the valve is always more than 40% of the
total pressure drop
.
b) Whenever corrective action requires to be linear and at the same rate
throughout the range of opening e.g. the level control of a constant cross
sectional vessel.

35
 c) Where the process lag is small and the proportional band is less than 10% .

5.3 QUICK OPENING PLUG

The flow characteristics in this type of valve will be maximum flow for minimum
travel. The plug is basically a flat disc with the addition as a linear contour for the first
25% of the stroke to counteract severe line shock. Hence it is also called as semi throttle
poppet or beveled plug. This trim is employed in normal on- off control applications. The
plugs are of reduced stroke and cylinder actuators are used for quick action.

5.4 TRIM

Trim generally refers to the removable internal parts of a valve which come in
contact with the flowing fluid. The components included in trim are different depending
on the type of valve, but they usually include packing retaining ring, stem, stem lock pin,
guide bushing, valve plug and seat ring(cage). The standard materials used for trim are
304 SS, 316 SS and precipitation hardened stainless steels(440-C for guide bushing)
Selection of the most suitable material must be made with due consideration of the
temperature, pressure differential across the valve plug and corrosive conditions.

36
VALVE PLUG AND SEAT RING (CAGE)
Fig 5.4

37
5.5 CAGE AND PLUG

Cages are employed in the control valves to reduce the aero dynamic noises and
to reduce the unbalanced forces which causes vibration in trim parts.

Flow characteristics of a cage valve are determined by the shape of the opening
provided within the cage, and can be either “equal percentage” (%V) or “linear” (LV). The
plug is available with Teflon seat.

Valve characteristics
Fig 5.5

38
5.6 PLUGS FOR ON-OFF SERVICE
The plugs for this purpose are
available in two types: with Teflon seat and
with stellite seat. Both types can provide
bubble-tight shut off.

On-off plug with Teflon seat

This type is used when the fluid

temperature is under 120 deg c and an
absolute seal must be ensured. For sizes
larger than 11/2 inches, the linear contoured
plug with Teflon seat is used for on-off
services.

On-off Plug with satellite seat

This type is used when the use of the

Teflon seat plug is unfeasible. The satellite
is finished with particularly careful lapping.

Fig 5.6

Steam Jacket
A steam jacket accessory is to be used with fluid causing condensations
when cooling down.

5.7 SPECIALITIES OF HIGH PRESSURE FEED WATER CONTROL VALVES

Feed water control valves face particular problems such as high and variable
pressure drops, high velocities, sudden temperature changes and flashing conditions all
of which impose severe mechanical and thermal shocks on the valves. Special care has
to be taken to decrease the turbulence to the minimum and thereby increase the life of
the internals as well as the body. Many design innovations have been incorporated by
renown manufacturers for such duties, which are explained below.

5.7.1 MUFFLE CHAMBER TRIM (Fig 5.7)

This is a cage guided throttle plug type, designed to reduce the discharge
pressure of flashing fluids where noise is a problem. The cage normally is extended
downstream of the seat and a series of baffles incorporated in the bore. Long operational

39
life is attained by using solid satellite for the valve seat and linings of the baffle orifices.
Pressure reflections from the baffles together with careful design of the plug combine to
effect a considerable noise reduction at valve outlet.

5.7.2 SPEICAL CAGE TRIM (ANTI-FLASH TRM)(Fig 5.8)

This embodies a cylindrical seat-ring and a guide with several tapped holes. The
size and number of holes (or ports) are dependent upon the flow coefficient and flow
characteristics. The holes are tapped (ports are rough finished) to provide turbulence
within themselves and the direction of flow so as to allow each high velocity jet to impinge
on each other within the seat ring throat, which in turn acts as energy absorber of the flow
medium.

The upstream potential energy developed by the inlet pressure is converted to

heat via fluid friction by massive turbulence within the throat of the seat ring itself, which
provides for continuous contact between parts within the valve and fluid. Hence,
discouraging cavity formation. It also provides pressure reducing with no pressure
recovery, thus precluding low pressure and within the valve which may fall below the
vapour pressure of the fluid

5.7.3 CASCADED TRIM (Fig 5.9)

This is designed to overcome the severe conditions imposed by extremely high

pressure drops, thus offering longer valve life with minimum maintenance. An extension
of the valve plunger in a guide downstream of the main valves seat and a series of
annular grooves or steps in one of them help produce a cascade effect each step
contributing to a pressure drop with minimum of vibrations. Thus the drop across the
valve seating surface is a fraction of the total and the internal stream velocities are greatly
reduced to attain minimum erosion, cavitation and noise.

In all the above designs, special materials for internals such as satellite, 17.4 PH
SS, Colmonoy-6 or 440-C are adopted to resist the duty and give trouble-free service.

40
Fig 5.7,5.8 and 5.

41
 CHAPTER 6

VALVE INSTALLATION

6.0 INTRODUCTION

The satisfactory performance of control valve depends on proper installation.

Correctly sized and selected control valve might fail in performance, if the installation has
not been carried out as per the requirement and established practices. And further it may
lead to serve damage to the piping or equipment installed down stream of control valve.
Safety of manpower and equipment is one of the prime considerations in any
industrial installation. While designing a control valve, adequate safety factors should be
taken into consideration, in selecting the material for body, and for internal parts of
control valve, keeping in view the pressure and temperature of the fluid to be handled.
Even after taking all precautions during design and manufacturing stage, of a control
valve, there is a possibility of leakage through gland or gaskets during commissioning or
at a later stage of operation.

6.1 INSTALLATION PRECAUTIONS

It is important and very essential, that the location for installing the valves be
selected in such a way that leakage does not harm the operator and equipment located
near by.In the event of shut down, control valves are likely to retain system pressure. This
pressure must be released before attempting for any maintenance work on these control
valves. Particularly in case of tight shut off valves installed along with block valves,
trapping of fluid at considerably higher pressure is possible. Even at low pressure toxic
fluids can endanger the life of a technician while opening the valve. In such application
adequate venting and draining facilities are essential in the piping system. Further, these
vents and drains may have to be terminated in safer locations.

It is a known fact, that the control valve can be considered as a variable

orifice and as such piping arrangement recommended for orifice assemblies would apply
to valve installation also to a great extent. It is always preferable to allow 10 to 20 pipe
diameters of straight run upstream and 3 to 5 pipe diameters of straight run down stream
of control valve. Straight run at inlet ensures the steady inlet pressure of the fluid at
different flow conditions. It is ideal to provide control valves with the facility for manual
operation. In that case location of control valve be easily identifiable by the operator.
Suitable monitoring instruments should be provided in the vicinity, so that the operator
can observe that change in the parameter while manually operating the control valve.

6.2 PREVENTIVE METHOD FOR THERMAL EXPANSION

the valves used for isolation application and handling high temperature fluids, will
experience the entrapment of fluid in the bonnet portion of the valve. This fluid
temperature may rise due to adjacent pipe or an external source. This will cause fluid
thermal expansion. Therefore the internal pressure in the bonnet section will rise and the

42
valve will not open due to high stem torque required. Following measures are adopted to
avoid over pressurization due to liquid thermal expansion.

1. For the valve to which hydrostatic test pressure is applied from same direction as
flow, a balance hole is provided to connect the disc pressure applying side of the
disc to the chest of main valve body.(refer fig. in next page).

2. For the valve to which hydrostatic test pressure is needed to be applied from both
inlet and outlet or from opposite side of flow, the outside balance pipe (a stop
valve is installed in between) should be provided from chest of main valve body
to the up-stream side, and when testing hydraulically, the balance valve should
be closed and while operating this valve be fully opened and locked.(refer fig in
next page).

3. For the valve of which flow direction may be changed by the operational
condition, the balance pipes with an intermediate stop valve shall be provided
from the chest of main valve body to both inlet and outlet of main valve, the stop
valve in high pressure side during operation shall be normally opened.(refer fig in
next page).

43
44
 CHAPTER 7

CONTROL VALVE INSPECTION PROCEDURE

7.0 INTRODUCTION

Control valves are essentially metallurgy intensive, and they have to withstand
extreme temperature, high-pressure, stresses and other usual environmental conditions.
In fact control valve applications call for special alloys containing FERROLIUM,
TITANIUM, ZERCONIUM etc, to cater the multifunctions of the valve. From design point
of view, and user point of view to ensure the quality the control valves should be
inspected to establish their viability for specific application. Inspection mainly comprises
of, material inspection, parts inspection, functional testing.

7.1. MATERIAL INSPECTION

7.1.1 PHYSICAL AND DIMENSIONAL CHECK

Valve components are made from castings and forge materials. Hence external
appearance inspection is required to check surface defects like blowholes, crack,
shrinkage’s, flow directions, batch no’s etc. Apart from these, dimensions, shapes,
profiles checks on random samples must be done depending on the importance of the
parameters checked.

7.1.2 NON-DESTRUCTIVE TESTING (NDT)

NDT is a versatile tool for maintaining the Quality of parts manufactured, and is
used for find out sub-surface and surface defects of material. Some of the important NDT
techniques are a) Radiographic examination b) Ultrasonic testing c) Magnetic particle test
d) Liquid penetrate check. All the these tests help in finding the internal soundness of the
material, parts and detect defects like blow and gas holes, porosity, cracks, shrinkage’s,
etc.

7.1.2.1 RADIOGRAPHIC EXAMINATION

X-rays OR Gamma rays are used for this type of examination. When a film
exposed to radioactive isotope like Cobalt 60 or Iridium 192, an invisible change is
produced in the film. When developed, the defects of material are exposed as dark
patches, indicating the defects and their intensity. The tests are carried out as per ASTM
standards class-III, ASTM reference standards E446 etc.

45
7.1.2.2. ULTRASONIC TESTING

This test is based on the fact, that impedance offered by the metals of standard
reference to the metals with the defects such as blowholes, cavities, to the sound waves
are different. This helps in identifying the subsurface defects in terms of depth and
magnitude. Valve body and bonnet castings and forgings are normally tested by this
method.

7.1.2.3 MAGNETIC PARTICLE INSPECTION

This test is carried out to find out the discontinuities in the ferro magnetic
materials. Normally used to find out surface defects of the objects. This inspection is of
three steps.

a) Establishing a suitable magnetic field in the test object.

b) Applying magnetic particles to the surface of the test body.
c) Examining the test object surface for accumulation of the particles.

7.1.2.4 LIQUID (DYE) PENETRANT INSPECTION

This is one of the oldest methods of NDT process. This is a routine check based
on penetrants seeping in to a discontinuity in the object body. Normally surface cracks or
porosity are detected by this method.

7.1.3 PARTS INSPECTION

All the components of valves need to be made precisely so that it would facilitate
a perfect assembly of mating parts. All the parts are subjected to

a) Dimensional inspection for length, diameter threads etc.

b) External appearance inspection.

c) Pressure resistance test.

d) Elasticity inspection

e) Accuracy test

f) Unit inspection

7.1.3.1 PRESSURE RESISTANCE TEST

Valve bodies have to be tested hydraulically for their internal soundness by

applying twice the design pressure of the valve for a period 10 minutes conforming to the
applicable standards.

46
7.1.3.2 ACCURACY TEST

Flow characteristic of the valve is dependent on the contour of the valve plugs
and seat finishing. Therefore conformity to the design dimensions is very important. Up to
3inch size, plug is inspected in the profile projected by magnifying the object to 10,20 or
30 times with optical profile checking device. Sizes above 3 inch will be directly
checked.Surface roughness and straightness of stem are also checked for good sealing
and longer life.

7.1.4 FUNCTIONAL TESTING

7.1.4.1 SEAT LEAKAGE TEST

Once the valve is assembled it is subjected to seat leakage test with plug in
closed position, without the actuator.

If it is a single seated valve, the leakage is checked by applying air pressure, and
the double seated valves with water pressure. In the case of single seated valves
leakage is measured with Rota meter calibrated to 0.01 l /min, and for double seated
valves leakages are measured with measuring JARS which will give direct result.

For leakages, less than 0.01 l /min, the leakage is measured by fixing a blind
flange with a 6mm diameter copper tube to one valve flange. This tube is immersed in
water and the air bubbles per min through water is counted, which gives direct readings
of the leakage through valve.

7.1.4.2 ACTUATOR TEST (pneumatic actuator)

Main parts of the actuator are the diaphragm casting, diaphragm and spring.
The diaphragm chambers (casting) with diaphragm are tested with cyclic loading for
about 10,000 times to assess their life span. After the test the diaphragm is checked for
physical damage (this test is done on random basis for every 10 pieces).
The valve spring is subjected to load at intervals of 25%, 50% and 100% in both
directions and the relationship for the movement with respect to load will reveal the
linearity as well as hysterisis if any present. Test for threshold sensitivity to determine no
deflection must be conducted for adjustment of spring tension.

7.1.4.3 VALVE PERFORMANCE INSPECTION

It consists of stroke test, valve open start and return point, linearity, hysterises,and
evaluation of flow coefficient ie.Cv.

7.1.4.4 STROKE TEST

The travel of the valve stem is tested by applying 0.2 to 1 kg/cm2 air pressure signal
to the actuator.The travel should be within +or- 3% of the rated travel. Then by applying
1.2kg./cm2 the over travel also will be checked to ascertain the life of the valve. Valve

47
stroke is shown in figure below. Normally the allowable over travel will be given by
manufacturer and depends on the type of valve.

Fig 7.1

7.1.4.5 VALVE OPEN START AND RETURN POINT

The open start point of valve and return point must be within the prescribed
tolerance in respect to the input pressure settings.

7.1.4.6 LINEARITY CHECK

The actual travel of 25%. 50% and 75% input, the valve travel in the opening and
closing direction are tested. The travel must be within the tolerances with respect to the
set travels. The graph shows the linear movement of valve stem in ideal conditions with
the input of 0.2 to 1,0 kg / sqcm & curves of stem travel with +1% and –1% deviations.
Ideally the travel must be linear.

48
 Fig 7.2

7.1.4.7 FLOW CO-EFFICIENT MEASUREMENT

The flow co-efficient “Cv” is defined as the number of US gallons per minute of
water that will pass through fully open valves for 1-psi pressure drop.

The valve to be tested will be mounted on the pipeline of it size. Clean water is
pumped under control pressure; the pressure drop is adjusted to one psi across the
valve, using throttling valves and manometer. The flow rate is then measured with
precession flow meters and the test can be carried out for 25%, 50%, 75% openings to
find out the relation at respective opening.

7.2 CONTROL VALVE AUXILLARY INSPECTION

The control valve performance mainly depends on the functional aspects at the
connected auxiliaries, such as Valve positioner, Air filter regulator, Air lock relay, and
position transmitters.

7.2.1. VALVE POSITIONER

A valve positioner provides (auxiliary air supply) necessary pressure to the

actuator so that the valve operates strictly as per the control signal in all circumstances
even if abnormal conditions such as excess Gland friction etc, occurs. Further, air

49
flow rate for pilot assembly, top &bottom nozzle leakage checking is carried out to find out
the air consumption and actual leakage respectively. No air leakage is permitted over the
top and bottom nozzles when the signal is either minimum or maximum.

7.2.2 AIR FILTER REGULATOR

These are tested to find out Regulator flow characteristics, Normal Air
consumption (more than 0.92 l / min is not permitted) and overall leakage.

7.2.3 REGULATOR FLOW CHARACTERISTICS

The inlet of the regulator is connected to the air supply and outlet to the rotameter
and pressure gauge. A supply pressure of 1.4 or 2.6 kg/cm2 is set at the inlet without flow
through regulator. Then air flow of 50 Nl / min is allowed through regulator, and the
pressure drop across the regulator should not exceed 10%.

7.2.4 OVERALL LEAKAGE

The air supply pressure is maintained to the maximum at its capacity or at

10kg.cm2, which ever is low, and soap solution is applied all over the joints. No leakage
is allowed.

7.2.5 AIR LOCK RELAY

These relays are used with control valves to lock in the loading pressure when
the supply pressure fails. (i.e. Lock in last position / Stay put condition).
This relay is subjected to pressure tight test, performance test, flow measurement and
cyclic test.

7.2.6 POSITION TRANSMITTER (motion transmitter)

The position transmitter can be either pneumatic or electrical. In pneumatic system

pressure gauge is used for position indication. If electrical transmitter is used then
position indication is by either a voltmeter (which indicates % of valve plug travel) OR a
travel limit switch (with light indication representing the valve plug position). The position
transmitter must be calibrated and checked for its performance.

50
 CHAPTER 8

NOISE IN CONTROL VALVES

8.0 INTRODUCTION

The noise levels in industrial location must be maintained to acceptable limits

considering the safety of human beings and structures in industrial area etc. The noise is
increasingly being regarded as a pollutant, which detracts from the quality of life. Noise is
an unwanted sound. The fluctions in the atmospheric pressure due to noise produces
unwanted auditory sensation the effect of this depends on the sound intensity and the
power transmitted in the direction of travel of noise. The unit of noise power is dB.

8.1 NOISE MEASUREMENT

Most Noise measurements are given in decibels (dB). The reasons for using a
relative instead of on absolute scale is because of the magnitude of its pressure range
involved. The smallest sound pressure by which a normal person can respond is 0.0002
bar. At above 200  bar the sound is felt, as well as heard, while above 2000 bar the
pressure levels are unbearable
.
It will be convenient to measure the actual sound pressure compare it with
reference level (0.0002 bar), and then express the result in decibels. Thus sound
pressure level (spl) can be given by scale between 0 and 120 dB in mathematical term
Spl = 20 log
Where p = measured pressure in  bar
p0 = 0.0002  bar

An increase of 3 dB represents a doubling of the sound intensity. Sound is

attenuated as the distance from the source to the observer is increased. When making
noise measurements from a valve, it is usual to take readings at points situated 45 0 from
the pipeline (both upstream and downstream) and at a radius of 1 meter away from the
valve body.

8.2 Sources of valve noise

Major sources of valve noises generated by the passage of the process fluid through the
valve can be due to a) mechanical vibration, b) cavitation, and c) aerodynamic.their
causes remedies are discussed here.

8.2.1 MECHANICAL VIBRATION

It is induced by the pulsations of the flowing fluid. Some times it can lead to
resonance of valve trim and fatigue failure of stem, guides, etc The slackness in the
bearing or guides can give rise to oscillation of the internals. In severe cases the trim may
go into resonance followed by rapid fatigue failure.

51
 Reductions of guide clearance for better guiding, increasing the stem size,
change of mass or stiffening up of the plug, reversal of flow direction are some of the
possible solutions. Resonance phenomena generally occur at frequencies between 2000
and 7000 cycles/sec.

8.2.2 CAVITATION
The collapse of vapour bubbles in the liquid due to pressure recovery in
downstream, of the valve orifice results in cavitation.

The velocity of fluid stream increases while passing through the control valve.
The velocity is maximum at veena contracta, hence pressure is less. If the pressure is
less than the vapour pressure of the fluid, vapours are formed causing voids or cavities in
the stream. Once the down stream pressure recovers vapour cannot exist. Then the
voids / bubbles are forced to collapse or implode. This implosion is the final stage of
cavitation and produces noise, vibrations and occasionally leads to mechanical damage
to valve parts.
Cavitations can be alleviated by reducing the pressure drop across the valve, by
selecting low recovery trims/multiple velocity head loss trims.

8.2.3 AERODYNAMIC NOISE

This is caused by the re conversion of kinetic energy through turbulence into
heat, down stream of throttling orifice handling compressible fluids. Aerodynamic noise
also produced by a gas (compressible fluids) accelerating to super sonic velocity at
critical or higher pressure drops through the trim. The resulting shock waves and general
turbulence at the fluid boundary generate sound which travels down stream. This noise is
worst of all, ranging from whistling sound to a heavy roar (eg. During boiler safety valve
discharge). Sound pressure levels of 130dBA have been noticed in severe cases.

Before final selection of valve, if the examination of flow data suggests the
probability of noise problem,adopting some of the methods listed here can alleviate this
problem.
a) By fitting special internals, improved trims with in the valve.

b) By fixing one are more fixed area devices in the down stream to reduce the
differential pressure across the valve in turn to reduce the noise
c) Heavy wall piping down stream of the valve.

d) Reducing the differential pressure across the valve by manipulating the upstream
and down stream pressures wherever possible.

It is always better to anticipate a noisy situation and cater for it than have to try to
remove the difficulty later on, because the problems involved in rectifying an already
noisy installation can be considerable.

52
53
 BODY AND BONNET OR COVER MATERIALS APPENDIX 1

SYMBOL STEEL RELATED TEMPERATURE LIMITATIONS APPLICATION

AMERICA
STANDARDS

LCB carbon ASTM -50 to 350 -50 to 350 Low temperature

A382 –LCB
WCB carbon ASTM -20 to 1000 -30 to 540 Steam , water, oil
A 16-WCB vapor gas and
general services.

WC1 carbon ATM -20 to 1000 -30 to 540 High temperature

Molybdenum A217 –WC1
½ % Mo

WC6 Chromium ASTM -20 to 1200 -30 to 645 Steam, Water, Oil
Molybdenum Vapor, Gas and
1.1/4% Cr.1%Mo General services

WC9 Chromium ASTM -20 to 1200 -30 to 645

Molybdenum A217-WC 9
2.1/4% Cr.1% Mo

C5 Chromium ASTM -20 to 1200 -30 to 645 corrosive –Erosive oil

Molybdenum A217-C 5 refinery service
5% Cr.1/2% Mo

C12 Chromium ASTM -20 to 1200 -30 to 645

Molybdenum A217-C 12
9% Cr.1% Mo
Selection of materials will be dependent upon actual service conditions
APPLICATION MATERIAL SERVICE TEMP.RANGE (°F) APPROX

Trim stainless steel standard trim material for most applications.

18-10-Mo(316)FMB) high corrosion resistance. On clean liquids will
Withstand pressure drop of 200 psi; on clean -100 to 800
gases, critical pressure drop and beyond

Stainless steel 18-8-Nb similar to above, but with slightly different

(347)(FCB) corrosion resistance properties. -300 to 800

Stainless steel 8-8-Ti

(321)(FDP) As above -300 to 800

hardened stainless Brinell hardness 400/450. good resistance to

steel (420)(FH) erosion; for high pressure drop service. Fair
corrosion resistance. Max trim size 4 in. -20 to 800

stellite face on cobalt-chromium-tungsten alloy. Brinell hardness on seats only

Stainless steel 360/400. good resistance to erosion for high -100 to 800.on
(18-10-Mo) pressure drop service on liquids, steam or gasses seats and guides
–100 to 1500

commonly face on As above , but high nickel chrome alloy brinell on seats and guides
stainless (18-10-Mo) hardness 535/630 -100 to1500

Manganese Bronze low pressure and temp. service, should not be -200 to 350
used where abrasive particles are present in the
fluid
 Monel 70% nickel, 30% copper alloy. High corrosion
Resistance, especially on alkalis and salt solutions. -300 to 1000
Recommended for reducing agents rather than
Oxidizing

Hastelloy ‘b’ 65% nickel, 30% moly alloy. High pressure -300 to 1000
Resistance against mineral acids (hydrochloric,
Phosphoric, sulphuric). Not recommended for
oxidizing agents.

Hastelloy ‘c’ 65% nickel, 18% moly 15% chrome alloy. High -300 to 1000
Corrosion Resistance against oxidizing agents,
nitric acid ,free chlorine, and acid solution of ferric
and cupric salts

Nickel High corrosion resistance against strong -300 to 1000

concentration of hot caustic soda and other alkaline.
or neutral salts. Not recommended for strong
oxidizing agents

III Bolts and Nuts

Stud bolt 1% chrome ¼ % Most regular applications. special alloys supplied when
moly steel required for special corrosion resistance.

Nuts High tensile

High treated steel
 APPENDIX 2

SPECIFIC GRAVITY OF WATER AT VARIOUS TEMPERATURES

°F °C G °F °C G °F °C G °F °C G
62 17 1.000 200 93 0.963 310 154 0.913 420 216 0.843
100 38 0.995 210 99 0.959 320 160 0.908 430 221 0.836
110 43 0.992 220 104 0.955 330 166 0.904 440 227 0.828
120 49 0.990 230 110 0.951 340 171 0.896 450 232 0.820
130 54 0.987 240 116 0.947 350 177 0.890 460 238 0.812
140 60 0.983 250 121 0.943 360 182 0.884 470 243 0.804
150 66 0.980 260 127 0.938 370 188 0.878 480 249 0.796
160 71 0.977 270 132 0.933 380 193 0.871 490 254 0.788
170 77 0.974 280 138 0.929 390 199 0.864 500 260 0.780
180 82 0.970 290 143 0.924 400 204 0.857 550 288 0.736
190 88 0.966 300 149 0.919 410 210 0.849 600 316 0.688
 APPENDIX 3

SPECIFIC GRAVITY OF COMMON LIQUIDS (AT 15 C /16F)

Acetic Acid 1.06 Ether 0.73 Naphtha 0.76

Astron 0.79 Ethyl Alcohol 0.789 Nitric Acid 1.50
Alcohol (Commercial ) 0.83 Fluoric Acid 1.50 Olive Oil 0.919
Alcohol (Pure) 0.79 Gasoline 0.72 Palm Oil 0.97
Ammonia 0.89 Gasoline (Natural)0.68 Pentane 0.624
Benzene 0.69 Glycerin 1.26 Petroleum Oil 0.82
Benzoic Acid 1.27 Hydrochloric Acid 1.19 Phosphoric Acid 1.76
Bromine 2.97 Hydrofluoric Acid 0.99 Rape Oil 0.92
Carbolic Acid 0.96 Kerosene 0.80 Sulphuric Acid 1.84
Carbonic Acid 0.92 Linseed Oil 0.94 Tar 1.00
Carbon Disulphide 1.26 MC Residuum 0.935 Turpentine Oil 0.87
Carbon Tetrachloride 1.60 Mercury 13.57 Vegetable Oils 0.93
Chlorine 1.56 Methyl Alcohol 0.796 Vinegar 1.08
Chloroform 1.50 Mineral Oil 0.92 Water 1.00
Distillate 0.85 Muriatic Acid 1.20 Water (Sea) 1.03
 APPENDIX 4
Physical properties of common gases
Name FORMULA Approx. . Specific gravity Specific heat
molecular Wt. relative to air ratio (at 1 atm)
Acetylene C2H2 26.0 0.90 1.26
Air - 29.0 1.00 1.40
Ammonia NH3 17.0 0.59 1.30
Argon A 40.0 1.38 1.67
Butane C4H10 58.0 2.08 1.11
Carbon di oxide CO2 44.0 1.52 1.30
Carbon monoxide CO 28.0 0.97 1.40
Chlorine Cl2 71.0 2.49 1.35
Cyalogen C2N2 52.0 1.81 1.26
Ethane C2H6 30.0 1.04 1.22
Ethyl chloride C2H5Cl 64.5 2.36 1.13
Ethylene C2H4 28.0 0.97 1.22
Fluorine F2 38.0 1.31 -
Helium He 4.0 0.14 1.66
Hydrobromic acid HBr 81.0 2.71 -
Hydrochloric acid HCl 36.5 1.27 1.40
Hydrogen H2 2.0 0.069 1.41
Hydrogen sulphide H2S 34.0 1.19 1.32
Krypton Kr 83.5 2.82 1.68
Methane CH4 16.0 0.55 1.32
Methyl chloride CH3Cl 50.5 1.78 1.20
Natural gas - 19.5 0.67 1.27
Neon Ne 20.2 0.696 1.64
Nitric oxide NO 30.0 1.036 1.40
Nitrogen N2 28.0 0.97 1.40
Nitrous oxide N2O 44.0 1.52 1.28
Oxygen O2 32.0 1.10 1.40
Pentane C5H12 72.0 - 1.09
Phosgene OCCl2 99.0 - -
Propane C3H8 44.0 1.56 -
Propylene C3H6 42.0 1.45 -
Sulphur dioxide SO2 64.0 2.26 1.29
Xenon Xe 131.0 4.53 1.66
 APPENDIX 5

CRITICAL PRESSURE OF VARIOUS FLUIDS

Bars (abs) lbf/im2 (abs)

Acetic Acid 58.0 841

Acetone 47.7 691
Acetylene 62.28 911
Air 37.7 547
Ammonia 112.8 1636
Argon 48.6 705
Benzene 48.3 701
Butane 36.4 528
Carbon dioxide 73.9 1072
Carbon monoxide 35.4 514
Chlorine 7702 1119
Dowtherm 'A' 32.1 465
Ethane 49.5 717
Ethylene 51.2 742
Freon 40.0 580
Helium 2.3 33
Hydrogen 13.0 188
Hydrogen chloride 82.6 1198
Isobutene 37.5 543
Methane 46.4 673
Methyl alcohol 79.7 1156
Neon 26.3 381
Nitrogen 34.0 493
Nitrous oxide 72.7 1054
Oxygen 50.4 730
Pentane 33.5 485
Phosgene 56.8 823
Propane 42.6 618
Propylene 45.6 661
Refrigerant 12 40.7 590
Refrigerant 22 49.4 716
sulphur dioxide 78.7 1141
water 221.3 3210
 APPENDIX 6

AMERICAN NATIONAL STANDARD FOR CONTROL VALVE SEAT LEAKAGE

PURPOSE
This standard establishes a series of seat leakage classes for control valves and
defines the test procedures.

SCOPE AND LIMITATIONS

1. Selection of a leakage class is not restricted as to valve design but acceptable values
for various commercially available designers are suggested for each class.

2. The standard cannot be used as a basis for predicating leakage at conditions other than
those specified.

3. The standard does not apply to control valves with a rated Cv less than 0.1

DEFINITIONS

CONTROL VALVE

1. A valve with a power positioning actuator for moving closure member to any position
relative to valve port or seat in response to and in proportion to an external signal. The
energy for a control valve actuator is derived from an independent source.

2. Control valve body subassemblies on which an actuator is to be mounted at some later

date are with in the intent of this definition.

3. Cv An experimentally determined valve sizing coefficient. (Ref. ISA S39.1, 2, 3 and 4)

4. Rated valve capacity. The quantity of test fluid (air or water) that would pass through the
valve at rated travel under, stated pressure conditions as determined by the appropriate
equations and manufactures ratings.

5. Rated travel. The valve travel at which the manufacturer’s rating is established.

6. Seat leakage. The quantity of test fluid passing through an assembled valve in the
closed position under the conditions as defined.
LEAKAGE SPECIFICATIONS & CLASSES

The maximum allowable seat leakage as specified for each class shall not exceed
the seat leakage in Table 1 using the test pressure as defined in section 5. For Class II
through IV each and every valve shall be tested.

CLASS I

A modification of any class II, III, or IV valves where design intent is the same as the
basicclass, but by agreement between user and supplier, test is required.

CLASS II

This class establishes the maximum permissible leakage generally associated with
commercial double seat. Double seat control valves or balanced single port control valves
with a piston ring seal and metal –to- metal seal, use the test procedure type A.

CLASS III

This class establishes the maximum permissible leakage generally associated with
class II, (4.2.2) but requires higher degree of seat and seal tightness. Use test procedure
Type A

CLASS IV

This class establishes the maximum permissible leakage generally associated with
commercial unbalanced single - port, single seat control valves and balanced single – port
control valves with extra tight piston rings or other sealing means metal –to-metal seats.
Use test procedure Type A

CLASS V

This class is usually specified for critical applications where the control valve may be
required to be closed, with out a blocking valve, for long periods of time with high differential
pressure across the seating a surfaces. It requires special manufacturing assembly and
testing techniques. This class is generally associated with metal seat, unbalanced single –
port, single seat control valves or balanced single port designs with exceptional seat and
seal tightness. Use test procedure Type B using water at the maximum operating differential
pressure.

CLASS VI

This class establishes the maximum permissible seat leakage generally associated with
resilient seating control valves either unbalanced or balanced single-port with “O” rings or
similar popular seals. Use test procedure Type C.
TABLE – 1

Leakage Maximum seat leakage Test procedure

class

CLASS I See Paragraph 4.2.1 None

Class II
See 4.2.2) 0.5% of rated valve capacity Type A
(See5.1)
Class III
0.1% of rated valve capacity Type A
(See 4.2.3) (See5.1)

Class IV
(See 4.2.4) 0.01% of rated valve capacity Type A
(See5.1)

Class V 5 x 10 -4 ml per minute of water per Type B

Inch of orifice diameter per psi differential (See5.2)
(5x10-12 m3 per second of water per mm of
orifice diameter per bar differential).
Class VI Leakage as per paragraph 5.3.4 as expressed Type C
In ml per minute versus port diameter. (See5.3)

TEST PROCEDURES

Test procedure type A.

 Test medium shall be clean air or water at 10-52 0C (50-125° F).

 Pressure of test medium shall be 3-4 bar (45-60 psig) or the maximum
operating differential pressure whichever is less.

 Leakage flow and pressure data shall be accurate to ± 10 percent of reading.

 The test fluid shall be applied to the normal or specified valve body inlet. The valve
body out let may be open to atmosphere or connected to a low headless-
measuring device.

 The actuator shall be adjusted to meet the operating conditions specified .The full
normal closing thrust as applied an air pressure, a spring or other means shall
then be applied. No allowance or adjustment shall be made to compensate for the
 increase in seat load obtained, when the test differential is less than the maximum
valve operating differential pressure.

 On valve body assemblies made for stock, tested without the actuator. A test
fixture should be utilized which applies a net seat load not exceeding the
manufacturer, s normal expected load under maximum service conditions.

 On water test, care shall be taken to eliminate air pockets in the vale body and
piping.

 The leakage rate thus obtained can then be compared to the calculated values for
Class 11,111, and 1V, in table 1.

TEST PROCEDURE TYPE B

 The test fluid shall be clean water at 10-520 (50-125f)

 The water test differential pressure shall be the maximum service pressure drop
across the valve plug, not exceeding the maximum operating pressure at room
temperature as determined by ANSI B16.1, B16.5, or B16.34, or some lesser
pressure by individual agreement (7 bars or 100 psi pressure drop minimum).
Pressure measurement accuracy is to be in accordance with paragraph 5.1.3.

 Test fluid shall be applied to the normal or specified inlet of the valve body. The
valve plug shall be opened and the valve body assembly filled completely with
water, including outlet portion and any downstream connecting piping and then
closed.

 The water test differential pressure as specified in 5.2.2 is then applied with the
actuator adjusted to meet the operating conditions specified. The net actuator
thrust shall be the specified maximum. Net actuator thrust above the specified
maximum is not to be used.

 When leakage flow is stabilized, the quantity should be observed over a period of
time sufficient to obtain the accuracy under paragraph 5.1.3.

 The leakage rate thus obtained shall not be greater than the value calculated from
the definition of maximum seat leakage for class V as shown in table 1. The orifice
diameter is understood to be the diameter at the point of seating contact at the
nearest 2 millimeters(1/16 inch)

TEST PROCEDURE TYPE C- CLASS VI

 Test medium shall be air or nitrogen gas at 10-50 deg c (52-125 F)

 Pressure of the test medium shall be the maximum rated differential pressure across the
valve plug or 3.5 bar (45 psi) whichever the least.

 The test fluid shall be applied to the normal or specified valve body inlet, and the outlet
connected to a suitable measuring device.

 With the control valve adjusted to meet the operating conditions specified (see
paragraphs 5.1.5, and 5.1.6) and with sufficient time allowance for stabilizing flow, the
leak rate shall not exceed the values in Table 2.

TABLE 2

Normal port diameter leakage

Millimeters inches ml per minute bubbles per minute
25 1 0.15 1
38 1.5 0.30 2
51 2 0.45 3
64 2.5 0.60 4
76 3 0.90 6
102 4 1.70 11
152 6 4.00 27
203 8 6.75 45

Bubbles per minute as tabulated are a suggested alternative based on a suitable

calibrated measuring device, in this case 0.25 inch (6.3 mm) O.D. x 0.032 inch (0.8 mm)
wall tube submerged in water to a depth of from 1/8 to ¼ inch (3 to 6 mm). The tube end
shall be cut square and smooth with no chamfers or burrs and the tube axis shall be
perpendicular to the surface of the water. Other operators may be constructed and the
number of bubbles per minute may differ from that shown in table 2 as they correctly
indicate the flow in ml per minute.

Provisions should be made to avoid over pressurizing of the measuring devices

resulting from inadvertent opening of the valve plug.
 APPENDIX 7
TYPICAL SPECIFICATION FOR CONTROL VALVE.

Client: Thermal station.

Project: TPS 2x210. MW.
Purpose: Condensate drain of SCAPH.
Quantity: 2x2
FLOW DATA :
Fluid: Condensate.
Temperature: 2250 C
In let pressure(P1) 15 ata.
Pressure drop (sizing) 0.927 kg/cm2 (6 % of p1)as fluid is flashing.
Diff pressure (shut off) 15 ata.
Flow rate (max) (nor.) 12000 kg/ hr.
S.G/Density/MW/Viscosity : 0.8771
Cv cal/ Design 15.4/24
II. VALVE SPECIFICATIONS:
Size body/port: 1 ½” x 1 ½”
Model depends on application &in consultation with supplier
End connections: ANSI 300 RF
Body material: A 216 Gr WCB(scph 2)
Trim material: AISI 316 Stelited.
Characteristics: Lc’ on-off.’
Plug guiding: Top.
Bonnet: Finned.
Gaskets: V-543.*
Action on air failure: Close.
Isolating valve: yes

ACTUATOR:
Model: Electrical / pneumatic
Spring range(Kg/Cm2) Type ‘ A ’with linear movement Max. Thrust 2000 Kg .Stroke – 25mm.

ACCESSORIES :
Positioner. Torque switches with holding relays, motion
Transmitter (0 – 120 ), position indicator.
OR
Pneumatically operated etc.
Hand wheel Side/Top: Yes(Top).
Limit switch Yes (2 nos)
IBR certificate: Yes.
Extra information: As applicable.

APPENDIX 8
 VALVES FOR DIFFERENT APPLICATIONS.

Location of application Characteristic Actuator Make/supplier

R.H Emergency block valve Flash flow linear Diaphragm Black&Barough
type
Feed water control valve =% VP – 6 I.L.P.
Feed water control valve Linear VP - 7 I.L.P.
S.H. Spray control valve Flash flow = % Diaphragm Black&Barough
R.H. Spray control valve ,, ,, ,,
SCAPH drain L.C. on-off Electrical I.L.P.(Roper)
Hot- well make-up control =% VA1D “
Steam to wagon heating =% VA2D “
C.B.D.expander drain level L.C. VA1R “
Auxiliary steam to deaerator Pr. =%V VA2D “ .
control
Cold reheat steam to ,, ,, ,, VA4D “
F.W.C. valve %V VP.7 “
Lo-load feed control ,, VP.6 “
Aux.steam to fuel oil- %C HTP “
-suction header

(this may not be a rule to use the same type of valve in all similar applications. users
are requested to understand each application, and select the suitable valve.)

APPENDIX 9
DIAPHRAGM- Nylon Reinforced Neoprene, Extra Large Area Assures Accurate Positioning
Of Inner Valve.

SPRING ADJUSTMENT-Allows 3 To 15 PSI Inner Valve Travel For All Line Pressures

TRAVEL INDICATOR-Handy Reference between Full Open to Full Closed.

PACKING CLAND-Graphite Asbestos or Teflon Packing Rings Assure A Tight Seal with
Minimum Friction.

INNER VALVE- V-Ported With Top And Bottom Skirt Guide.

BOOT-Available In A Selection Of Materials And End Connections.

DIVERTING PATTERN-One Inlet, Two Outlets, V-Port Inner Valve Provides Modified Linear
Flow Characteristic For Each Outlet.

MIXING PATTERN-Two Inlets, One Outlet, V-Port Inner Valve Provides Modified Linear
Flow Characteristic For Each Inlet.

LUBRICATOR-(Not Shown) Valve Application Determines Type Of Lubricant Furnished.

Lubricator Isolation Valve Supplied With Cast Steel Control Valves.

DIVERTING OPERATION

The Inner Valve Is Located Outside The Two Seat Rings. For A Throttling Positions
The V-Port Plugs Always Close Against The Flow Of The Common Inlet, Adding To
Operational Stability. The Possibility Of ‘Slamming’ And ‘Hammer’ Are Eliminated
Even When The Inner Valve Is Just Off The Seat.

MIXING OPERATION

The Inner Valve Is Located Inside The Two Seat Rings. For All Throttling Positions
The V-Port Plugs Always Close Against The Incoming Flow. Internal Forces
Developed By The Two Inlet Oppose Each Other, Creating Little If Any Unbalance
And Thereby Assuring Against The Possibility Of ‘Slamming’ And ‘Hammer’ When
The Inner Valve Approaches The Critical Position Just Off The Seat.

Valve size ” ” 1” 1 1/4”1 ”2” 21/2”Mixing

½
¾

5.37.211.320.130.548.078.8Diverting5.57.611.921.132.050.482.7Valve
size3”4”5”6”8”10”12”Mixing1011422143766629311100Diverting106149225396695
9781270
APPENDIX 10
Throttle Plug Control Valve recommended for low pressure drop applications. The
machined contour around the plug periphery makes the valve suitable for fluids carrying
suspended solids.

APPENDIX 11
V PORT CONTROL VALVE
 V-port Control valve used for precise throttling control. Typical applications such as feed
water control, steam pressure radiation, heater level control, etc.

APPENDIX 12

VOLUMETRIC RATE OF FLOW

Litre Per Litre Per Cubic meter Cubic foot Cubic foot UK gallon UK gallon US barrel
 Per minute per day
second minute Per hour Per hour Per minute Per minute
US gal/min US
t/s t/min M3/h Ft3/h Ft3/m US gal/min
barrel/d
1 60 3.6 127.133 2.1189 13.2 18.85 543.439
0.017 1 0.06 2.1189 0.0353 0.22 0.264 9.057
0.278 16.667 1 35.3147 0.5886 3.666 4.403 150.955
0.008 0.472 0.0283 1 0.0167 0.104 0.125 4.275
0.472 28.317 1.6690 60 1 6.229 7.480 256.475
0.076 4.546 0.2728 9.6326 0.1605 1 1.201 41.175
0.063 3.785 0.2271 8.0209 0.1337 0.833 1 34.286
0.002 0.110 0.0066 0.2338 0.0039 0.024 0.029 1

FORCE

Newton Kilonewton Kilogram-force * Pound-force

N kN Kgf lbf
1 0.001 0.102 0.225
1000 1 101.97 224.81
9.807 0.0098 1 2.205
4.448 0.0044 0.454 1

MOMENT OF FORCE

Newton Kilonewton Kilogram force Pound force Pound Foot

Meter (N M) Meter (kN m) Meter (Kgf m) Inch(Lbf in) (Lbf ft)
1 0.001 0.102 8.85 0.738
1000 1 101.972 8851 737.6
9.807 0.0098 1 66.8 7.233
0.113 1.13*10-4 0.0115 1 0.083
1.356 0.0014 0.138 12 1

APPENDIX 13
 Bibliography

1. Valve users manual edited by J.kemplay.

2. Lyons Encyclopedia of valves by Jerry L. Lyons , P.E.
Carl . L. Askland.jr.
3. Control valves lecture notes by S. Raghavachari

4. Course meterial of ILP.

5. Technical brochures of –

a) Blakeborough valves.
b) Publications of BHEL.
C) Fisher governor
d) ILP product catalogue.
e) Masoneilan
f) Bailey Britain
g) Bacon rotork controls
h) Keltron control

6. Technical papers from power magazines.

7. NPTI control & instrumentation manuals

8. Control valves lecture notes by S. Karthikeyan ILP.

9. Control valves lecture notes by T.S.Nambiar ILP

10. Control valves lecture notes by G.K.Pillai ILP.