Control Valves - inst2JNTU - 2014

A Presentation
on Control Valves
G . SRIDHAR
INSTRUMENTATION
NFCL
NAGARJUNA FERTILIZERS AND CHEMICALS LIMITED
CONTROL VALVES
A VALVE IS A DEVICE USED FOR THE CONTROL OF
FLUID FLOW
A CONTROL VALVE IS A POWER-OPERATED DEVICE
USED TO MODIFY FLUID FLOW RATE IN A PROCESS
SYSTEM.
A VARIABLE ORIFICE
MOST USED FINAL CONTROL ELEMENT IN CLOSED
LOOP
CONTROL VALVE VERSUS MECHANICAL

VALES
Mechanical Valves will be operated by the
operator in the field where as Control Valves

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

A CONTROL LOOP HAS THREE
MAJOR
COMPONENTS
SENSING ELEMENT:
A DEVICE WHICH MEASURES PROCESS VARIABLE.
CONTROLLER:
PROVIDES A CORRECTIVE OUTPUT SIGNAL.
CONTROL VALVE:
THE FINAL CONTROL ELEMENT.
TYPICAL WIRING OF A CLOSED LOOP
CABINET
FIELD
PT
CSS
JB
BARRIER
IN
CATP IN
JB
BARRIER
OUT
CATP OUT
I/P
PV
DCS
PIC
CONTROL VALVE PARTS
1.Body
2.Yoke
3.Actuator
BODY
IT IS THE PRESSURE CARRYING PART
AND MEETS ALL THE APPLICABLE
PRESSURE, TEMPERATURE AND
CORROSION REQUIREMENTS.
BODY ASSEMBLY CONSISTS OF

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

a. TO PROPORTION THE VALVE ORIFCE
PER THE VALVE CHARACTERISTICS
b. TO
SHUT OFF TIGHTLY
AREA
AS
TRIM MATERIALS
BRONZE
SS-316
SS-316 + STELLITE
440C SS HARDENED
17-4 PH SS
CERAMIC
HVD
BONNET
ENCASES
THE ACTUATOR AND VALVE
ALLOWS
STEM
DESIGNED
TO
PACKING
MOVEMENT
MEET TEMPERATURE RANGE
IN HIGH TEMPERATURES AND BELOW FREEZING

TEMPERATURE SERVICES, EXTENSION BONNET IS
USED TO ISOLATE THE PACKING
GLAND PACKING
TO PREVENT THE LEAKAGE

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

ASBESTOS
GENERALLY NOT USED NOW

TEFLON
- TEMPERATURE RANGE
- 40 TO 230 Deg C
TEFLON WITH GLASS FIBER UPTO 455 Deg C IN EXTENDED
BONNET
TEFLON IMPREGNATED ASBESTOS - -70 TO 230 DEG C
GRAPHITE
NON- OXIDISING SERVICE- 15 TO 535 DEG C

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

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

DERIVED FROM A SUMMATION OF FORCES ON THE
VALVE PLUGS ADOPTING THE POSITIVE DIRECTION
,DOWNWARD .
(STEADY STATE EQUATION) PA - KX - PV AV = 0
PRES.
DROP.
AV
PV
EFFECTIVE INTRANAL
VALVE AREA
CONTROL VALVE OPERATION
CONTROL VALVE TYPES

THERE ARE TWO BASIC TYPES OF CONTROL VALVE
A) ROTARY MOTION VALVES

B) LINEAR MOTION VALVES
CONTROL VALVE CLASSSIFICATION

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

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

SINGLE
SEATED
DOUBLE
CAGE
SEATED
GUIDED
SPLIT-BODY
ANGLE
VALVES
THREE
WAY VALVES
SINGLE SEATED VALVES

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

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

LARGER AND HEAVIER THAN
SINGLE SEATED DESIGN
POOR
SHUT OFF
SEMI-BALANCED
HENCE
SMALLER ACTUATOR SIZE
AIR TO OPEN OR AIR TO

CLOSE CONFIGUTATIONS CAN
BE CHANGED EASILY TO
THE REQUIRED VALVE

FAILURE
NOT
WIDELY USED
DOUBLE SEATED VALVES

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

o
HIGH
FLOW
CAPACITY
USED FOR MIXING AND

DIVERTING FLUID.
HIGH
LEAKAGE CAPABILITY
CONSISTENT WITH
NORMAL SINGLE SEATED
GLOBE VALVE.
RANGEABILITY
ANGLE VALVE
EROSION
FLASHING
HIGH
TO
TO
ANGLE
TYPE
APPLICATIONS
APPLICATIONS
PRESSURE
DROP APPLICATIONS
AID SPECIAL PIPING ARRANGEMENT

AID DRINAGE
SPLIT-BODY VALVES
VARIANT
OF
SINGLE
SEAT VALVE
USED IN SLURRY, GUMMY AND

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

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

WILL BE ABOUT 25% LESS
THAN UNLINED VALVES
USED
IN CORROSIVE, TOXIC
APPLICATIONS
LIMITED PRESSURE AND

TEMPERATURE CAPABILITIES
POOR CONTROL
OPENING
OVER
50%
ROTARY MOTION
TYPES OF CLOSURE
1. BALL
2. BUTTERFLY
FEATURES
i.
STREAMLINED FLOW PATH

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

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

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

(BASED ON flow CHARACTERISTICS)
LINEAR
Q
U
EQUAL
PERCENTAGE
QUICK
OPENING
A
R
O
P
E
N
I
N
FLOW CHARACTERSTICS
IT IS THE RELATION BETWEEN
THE FLOW RATE
THROUGH THE CONTROL VALVE AND PLUG TRAVEL WHEN
A CONSTANT PRESSURE DIFFERENTIAL IS MAINTAINED
ACROSS THE VALVE
THIS IS ACHIEVED BY VARYING THE FLUID FLOW AREA
WITH RESPECT TO THE SHAPE
OF THE PLUG IN A
CERTAIN MANNER
FLOW CHARACTERSTICS
QUICK OPENING
THIS TYPE OF CHARACTERSTICS

PROVIDES MAXIMUM
CHANGE IN FLOW RATE AT LOWER VALVE TRAVELS
AS THE PLUG BOTTOM IS FLAT WITH A FAIRLY LINEAR
RELATIONSHIP , SO THE OPENING WITH A SMALL
SIGNAL WILL GIVE THE MAXIMUM FLOW RATE
THE COMMON APPLICATION
OF THE VALVE
IS ON -OFF
FLOW CHARACTERSTICS
LINEAR
CHARACTERSTICS:
Linear trim provides equal increases in flow rate for

equal increases in plug lift. Thus the flow rate is
linear with plug position throughout its travel. This type
of trim should be specified if the control valve is to
absorb most of the system pressure drop.
FOR
LEVEL CONTROL SERVICE
CONSTANT PRESSURE
MAJOR PRESSURE
VALVES
DROP ACROSS THE VALVE
DROP IS NOT THROUGH THE
FLOW CHARACTERSTICS
EQUAL PERCENTAGE
Equal percentage
in rate of flow
this case small
in lifts as the
towards the full
trim provides equal percentage

for equal increments of plug
flow passes correspond to large
plug first leaves the seat and
position.
increase
lift. In
changes
vice-versa
MAJOR PORTION OF SYSTEM PRESSURE

IS NOT THROUGH VALVE
VARIABLE PRESSURE
FOR TEMPERATURE ,FLOW AND PRESSURE

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

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

SINCE VAPOR BUBBLES FLOW IN PORT,
DENSITY OF FLUID DECREASED, WHICH
LEADS TO REDUCED FLOW
THE
CAVITATION
HOW TO OVERCOME CAVITATION

1.
PRESSURE DROP STATGING:

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

2.
EXPANDING FLOW AREA:

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

methods.
a. Providing higher size valve to reduce the
velocity
b. Providing hardened body/trim material, to resist
against erosion.
NOISE
There are basically three types of
Noises.
Mechanical
Vibration:
It is caused by the response of internal components within
a valve to turbulent flow through
the valve.
Aerodynamic
Noise:
It is a direct result of the conversion of the mechanical
energy of the flow into acoustic energy as the fluid passes
through the valve restrictions.
Hydrodynamic
Noise
Liquid flow Noise, Cavitation Noise, and Flashing Noise
can be generated by the flow of a liquid through a valve
and piping system.
METHODS TO REDUCE NOISE

Cavitation Noise can be eliminated by preventing Cavitation by
special designs. (Low
DB Anti Cavitation Valves ).
Path Treatment:
Increasing Pipe Schedule: An increase in pipe schedule is an
effective means to reduce control valve noise.
Increasing Pipe
Insulation: Insulation with sufficient
pipe
thickness
effectively reduces control valve noise or radiated
noise.
In Line Silencers: In Line Silencers
are effective in
reducing noise as they installed directly downstream of the
valve. These silencers dissipate the noise within the fluid
stream .
Source Treatment:
Adiabatic flow with friction:
It is to reduce pressure much
like that pressure loss which occur in

a long pipeline .
This effect is produced by letting the fluid pass through
the number of restrictions providing torturous flow pattern
dissipating energy through high head loss rather than through
shock waver.
FLOW COEFFICIENT (Cv)

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

and accurately estimate the required size of a restriction in
any fluid system.
Cv
FOR LIQUID SERVICE

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

PNEUMATIC POSITIONERS
SOLINOID VALVES
AIR FILTER REQULATER

ASSEMBLY
POSITION TRANSMITTER
HAND WHEEL
ACCUMULATOR
AIR LOCK RELAYS
PRESSURE RATINGS & TEMPERATURE

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

SELECTION CRITERIA
CORROSION
BY THE PROCESS FLUID

EROSION BY ABRASIVE MATERIAL
CAVITATION AND FLASHING SERVICES
USUALLY PIPE MATERIAL INDICATES BODY
MATERIAL, HOWEVER DUE TO HIGHER VELOCITY
OFTEN PIPE AND VALVE MATERIALS DIFFER
CONTROL VALVE
CLASS
CLASS
CLASS
II
LEAKAGE
NOT SPECIFIED
0.5% RATED VALVE CAPACITY
CLASS
III
0.1 % RATED VALVE

CAPACITY
CLASS
IV
0.01% RATED VALVE CAPACITY
CLASS
CLASS
VI
5*10-4ml per min. OF WATER

PER INCH OF ORIFICE
DIAMETER PER PSI
DIFFERENTIAL
LEAKAGE EXCPRESSED IN ML
PER MINUTE VERSUS PORT
DIAMETER
ACCESSORIES OF THE
CONTROL VALVES
AIR
FILTER
VALVE
POSITIONER
VOLUME
QUICK
AIR
LIMIT
REGULATOR
BOOSTER
EXHAUST
LOCK
RELAY
SWITCHES
SOLENOID
VALVE
POSITIONERS
A device attached to an actuator that receives an electronic
or pneumatic signals from the controller and compares this
signal to the actuators position.
A HIGH-GAIN PROPORTIONAL CONTROLLER

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

i.e)fine resolution.
Allow use of characteristic cams.
Packing Box Friction, Actuator Hysteresis, Corrosion, Lack of
Lubrication, Unbalanced forces in Plug, Non linearity's in valve
actuator will not have impact on valve accuracy.
Allow Split Ranging.
Overcome seating friction in rotary valves.
Facilitate operation when the higher number in the bench-set
range is greater than 1ksc
Permit use of piston actuators
Allow distance between controller and control valve using the
advantage of
4-20ma signal
Action of
the valve can be reversed
SOLENOID VALVES
Solenoid valves are used to bring the Control valve to the
fails safe state condition (i.e. Fail Open or Close) by
venting the air from the Actuator.
Application : Used
State is required.
in all Control Valves where Fail
Safe
VOLUME BOOSTER
Volume Boosters are used to increase the air flow to and
from an actuator beyond the capacity of the usual positioner.
The output Pressure is same as the inlet pressure
To be most effective ,the booster should be located near
the actuator and connected to it by tubing at least
3/8
inches in diameter.
Applications: Fast throttling action is required, Big size
Actuators , Antisurge Control Valves.
QUICK EXHAUST
Quick Exhaust valves are used to increase the Control valve
stroking speed (open or close) fully in only one direction.
The Same process can be achieved with Solenoid valves ,but
the speed is less.
It is used only for full opening or closing , controllable
stroking speed can be achieved through Volume Boosters.
Applications: Antisurge Control Valves, Vent Valves
AIR LOCK RELAY

When the supply pressure falls below a value set by the
spring the Air Lock valve closes and locks the air in the
Actuator.
This makes the Control valve opening position holds at the
same position before air supply failed.
Trip relay is similar to Air Lock relay. It is used to allow

air from a local reservoir to drive the actuator to the safe
position when the air supply fails.
Applications: Piston Type Actuators to achieve Fail state
CONTROL VALES ORIENTATION
THANK
YOU
G . SRIDHAR
INSTRUMENTATION
NFCL

Control Valves - inst2JNTU - 2014

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Control Valves - inst2JNTU - 2014

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A Presentation

NAGARJUNA FERTILIZERS AND CHEMICALS LIMITED

NAGARJUNA FERTILIZERS AND CHEMICALS LIMITED

CONTROL VALVE VERSUS MECHANICAL

operator in the field where as Control Valves

NAGARJUNA FERTILIZERS AND CHEMICALS LIMITED

NAGARJUNA FERTILIZERS AND CHEMICALS LIMITED

NAGARJUNA FERTILIZERS AND CHEMICALS LIMITED

ELEMENTS OF CLOSED LOOP

NAGARJUNA FERTILIZERS AND CHEMICALS LIMITED

TYPICAL WIRING OF A CLOSED LOOP

CONTROL VALVE PARTS

BODY ASSEMBLY CONSISTS OF

NAGARJUNA FERTILIZERS AND CHEMICALS LIMITED

NAGARJUNA FERTILIZERS AND CHEMICALS LIMITED

FUNCTIONS OF TRIM ARE

SHUT OFF TIGHTLY

NAGARJUNA FERTILIZERS AND CHEMICALS LIMITED

NAGARJUNA FERTILIZERS AND CHEMICALS LIMITED

THE ACTUATOR AND VALVE

IN HIGH TEMPERATURES AND BELOW FREEZING

NAGARJUNA FERTILIZERS AND CHEMICALS LIMITED

TO PREVENT THE LEAKAGE

SHOULD WITHSTAND PROCESS TEMPERATURE

SHOULD NOT REACT WITH PROCEE MEDIUM

GLAND PACKING MATERIALS

GENERALLY NOT USED NOW

NON- OXIDISING SERVICE- 15 TO 535 DEG C

NAGARJUNA FERTILIZERS AND CHEMICALS LIMITED

NAGARJUNA FERTILIZERS AND CHEMICALS LIMITED

NAGARJUNA FERTILIZERS AND CHEMICALS LIMITED

NAGARJUNA FERTILIZERS AND CHEMICALS LIMITED

VARIABLE AIR PRESSURE IS APPLIDE TO A FLEXIBLE

THE FOLLOWING EQUATION CAN BE

NAGARJUNA FERTILIZERS AND CHEMICALS LIMITED

CONTROL VALVE OPERATION

NAGARJUNA FERTILIZERS AND CHEMICALS LIMITED

CONTROL VALVE TYPES

A) ROTARY MOTION VALVES

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CONTROL VALVE CLASSSIFICATION

NAGARJUNA FERTILIZERS AND CHEMICALS LIMITED

GENERAL AND EXTREME SERVICES

NAGARJUNA FERTILIZERS AND CHEMICALS LIMITED

NAGARJUNA FERTILIZERS AND CHEMICALS LIMITED

NAGARJUNA FERTILIZERS AND CHEMICALS LIMITED

VARIOUS TYPES OF GLOBE VALVES

NAGARJUNA FERTILIZERS AND CHEMICALS LIMITED

SINGLE SEATED VALVES

NAGARJUNA FERTILIZERS AND CHEMICALS LIMITED

SINGLE SEATED VALVE

Packing Flange Stud

Packing Flange Nut

Lantern Ring (Optional)

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Body Stud Nut

Seat Ring Gasket

DOUBLE SEATED VALVES

AIR TO OPEN OR AIR TO

THE REQUIRED VALVE

NAGARJUNA FERTILIZERS AND CHEMICALS LIMITED

DOUBLE SEATED VALVES