Control Valve Theory & Sizing
The control valve, commonly named the final control
element of control contains a pneumatic device that
converts the control signal from the controller in
action, regulating the process fluid flow.
Valves make up approximately 15% of the total
expenditure for the materials and equipments for the
refinery or chemical processing industry.
Valves are used to handle variety of liquids , gases ,
steam, air etc.
Specification Of Valves
Flow medium
Flow : kg/hr or Nm3/hr Max/Min/Normal
Inlet pressure : kg/cm2 Max/Min/Normal
Outlet pressure:kg/cm2 Max/Min/Normal
Max. allowable diff. Pressure : kg/cm2
Density of medium : kg/m3
Viscosity
Cv : Valve Flow Coefficient
Specification Of Valves
Operating temperature - Deg. C
Design Pressure / temp.
End connection
MOC desired
leak Tightness required
Actuator : Pneumatic / electrical
Max. compressed air available : kg/cm2
Fail Safe Action
Category Of Valves
ON - OFF SERVICES :- Gate, Ball, Diaphragm, Plug,
Butterfly valves.
THROTTLING SERVICES :- Globe, Butterfly,
Diaphragm, Pinch valves.
NON - REVERSE FLOW :- Check valves.
Gate Valves
The Gate Valves are characterized by a sliding gate
which is moved by the stem perpendicular to the
direction of flow.
Application :- It is used for on-off application. Suited
for high temperature and pressure use with variety of
fluids. They are not primarily used for slurries, viscous
fluid etc.
Gate Valves
ADVANTAGES :
Low pressure drop when
fully open and tight sealing
DISADVANTAGE
Causes Vibration, seat disc
wear in partial open
condition. Slow response
characteristic and require
large actuating force.
Globe Valves
In Globe Valves disc or plug is moved on and off the seat.The
seat opening is directly proportional to the travel of the plug.It
is short stem travel, high seating capacity, large pressure drop
& high flow controllability.
Application :- It is used primarily for throttling purposes. It
may be considered a general purpose flow control valve.
Specifically very widely used for high temp. application.
Globe Valves
ADVANTAGES : Faster to
DISADVANTAGE Seat disc
open or close, most reliable
form of seating, throttling to
control the flow to any desired
wear in partial open condition.
degree, positive shut-off
Plug Valves
It consist of body, plug and cover. The plug is tapered or
cylindrical. In the open position, the bore in the plug connects
the inlet and outlet ends of the valve providing straight line
flow.
Application :- The plug valves are extensively used in
refinery, petrochem and chemical industries and for general
purpose involving on off services.
Plug Valves
ADVANTAGES : Normally
DISADVANTAGE Plug
small in size, require less
headroom and available in
wide range of materials. They
provide tight shut off, quick
opening and low pressure
drop.
valve may be subjected to
galling.
Ball Valves
It is improvisation of the plug valve. It is basically a ported
sphere in a housing.The seat matching the ball is circulars so
that the seating stress is circumferentially uniform. The seats
are usually made up of PTFE which is inert to all chemicals,
has low coefficient of friction and resiliency.
Application :- It is used for flow & pressure control and shut
off and for corrosive fluids, slurries, normal liquid & gases.
For high temp. & pressure
Ball Valves
ADVANTAGES : Low
pressure drop, tight shut
off, quarter turn operation,
easy to maintain, low
torque. They are small in
size and low in weight.
DISADVANTAGE
PTFE seats are subjected to
extrusion if the valve is used
for throttling. Fluid trapped
in the ball in the closed
position may cause problem
of build up of vapor pressure
& corrosion.
Butterfly Valves
They are rotary valves with a disc rotating at right angles
within a pipe section body.
The stem passes through this disc and is supported by
both ends of the body.
The shaft is ensured to the disc either by bolts or pins.
Rotating the stem through 90 degrees. Fully opens or
closes the valves.
Application :-Large flow control, Low pressure
application where leakage is unimportant.
Butterfly Valves
ADVANTAGES :
Simple , compact form, quick
opening, good control,large
flow, low pressure drop and
low weights and costs.
DISADVANTAGES:
No tight shut off.
Diaphragm Valves
The flexible diaphragm is connected to a support member
known as compressor, which represent the closure
member. When the valve is opened the diaphragm is lifted
out of the flow path and the fluid has a smooth
streamlined flow. When the valve is closed the diaphragm
is tightly seated against the seat in the body known as the
weir. The diaphragm is of NEOPRENE
Application :- Used for corrosive liquids at low temp. and
pressure .
Diaphragm Valves
ADVANTAGES : The
diaphragm completely keeps
the working parts in isolation
from the process fluids.
Simple in construction, easier
to operate and maintain.
DISADVANTAGES: Not
for high temp. and pressure.
Control Valve Principal Of Operation
It is based upon balanced forces between pneumatic force
from the diaphragm against a mechanical force produced
by the actuator spring.The control valve works with a
pneumatic signal 3 to 15 psi. The motion starts at 3 psi and
ends at 15 psi.
Control Valve Operational Forms
AIR TO
AIR TO
CLOSE:- 3 PSI FULL OPEN
15 PSI FULL CLOSE
OPEN : 3 PSI FULL CLOSE
15PSI FULL OPEN
At pressure higher than3 psi applied on diaphragm,it will start
overcoming the spring force and move diaphragm plate which in turn
moves stem connected and operates the plug.
Fail Safe Operation
AIR FAIL TO OPEN:AIR FAIL TO CLOSE:-
VENT PORT
ACTUATOR
POSITIONER
YOKE
VALVE BODY
CONTROL VALVE- HART POSITIONER
Components Of Control Valve
Actuator
Body
Trim
Diaphragm
Diaphragm plate
Actuator stem
Actuator spring
Seat
Component Of Control Valve
Travel
Indicator
Valve stem
Gaskets
Yoke
Hand wheel
DOME
SPRING
DIAPHRAGM
AIR SIGNAL
STEM
COUPLER
INDICATOR
SCALE
GLAND
BONET
PLUG
OUTLET
VALVE SEAT
INLET
VALVE BODY
MOTOR OPERATED
VALVE
Terminology
Flow Co-efficient (Cv) :The flow of
water (G=1, T= 6 to 34 deg. C) through the valve at full
lift in U.S gallon per minute with a pressure drop
across the valve of 1 psi.
Characteristic
Curves
FLOW %
QUICK OPENING
LINEAR
EQUAL %
VALVE LIFT %
Linear :Flow is directly proportional to lift at constant
pressure drop
Equal Percentage :Flow changes by a constant percentage of its
instantaneous values for each unit change in lift.
Modified flow:- Combination of linear and equal
percentage
Quick Opening :Flow increases rapidly in a linear relationship with
plug lift reaching a max. value at a low lift.
On-Off service
Guidelines For Control Valve
Specification
Valve trim is of stainless steel
Harden SS or Stellite is used for
Pressure drop of 150 psi or more
Steam
Slurry fluids
More temp
Teflon packing for les than 200 deg. Temp
Asbestos used above 200 deg temp
Valve Positioner
Valve requiring extra force due to process condition such as
Large pressure drop,Temp control,Large size , Split range
control