CONTROL VALVES

ISA Lima Peru October 2010 Jorge Souza

AGENDA
Valve Types Basic Components Piping Connections Pressure Ratings Materials Operation Concept Fire Safe Construction Control Technical Issues Flow Characteristic Curves Instrumented Air Quality Noise, Cavitation and Flashing Control Valve Sizing Cv Severe Service Applications
2

Valve Types

Manual Automated on-off Control

- by application

- type of operator - lever, gearbox or other. - type of actuator - pneumatic SA or DA, electric or other. - type of actuator - pneumatic SA or DA, electric or other. - type of positioner - smart, electronic or pneumatic.

Other

- safety relief - self operated (regulator) - check (non return) - multi port - steam trap - sample valve - etc.
3

Valve Types

- by construction

Butterfly 2 and 3 excentric

Top Entry Balls Segment

Excentric Plug

Globe

BASIC COMPONENTS
TRIM

BODY SEAT, PORT, CONNECTION, STEM ACTUATOR PNEUMATIC, ELECTRIC, SPECIALS

DOUBLE ACTION X SINGLE ACTION

POSITIONER PNEUMATIC, ELECTROELECTRO-PNEUMATIC, DIGITAL

5

PIPING CONNECTIONS

Connections

Screwed Wafer (clamp between flanges) Wafer Lugged (single flanged) Flanged

Flat and raised face, surface finish, ring type joints.

Weld

Socket weld, butt weld, extended butt weld.

Other

Special clamping systems.

Wafer Type

Lugged

Flanged

10

Welded

11

Clamp ring connection

12

PRESSURE RATING

13

Pressure Rating

Describes the ability of the valve (or piping system) to withstand the forces imposed by the temperature and pressure of the internal fluid. It depends on the thickness of the pressure retaining parts and the strength of the materials they are made from. The limits are expressed in tables or graphs of pressure / temperature for particular material. Ratings are expressed as: - ANSI Class 150, 300, 600, 900, 1500, 2500, 4500. - DIN PN 10, PN 16, PN 25 , PN 40, PN 64, PN 100 . - JIS PN 10K, PN 16K, PN 20K, PN 30K, PN 40K, PN 63K

Rating Pressure x Temperature curves

15

Rating - Pressure / temperature tables

Body Material Ratings

100% 90% 80% 70% Strength 60% Based on 50% ANSI 300# 40% 30% 20% 10% 0%
55 0 25 0 15 0 35 0 45 0 65 0 75 0 50

Carbon Steel Chrome Moly Stainless Steel

Temperature Celsius Degrees

ANSI X DIN
Pressure Class PN (barg) 10 16 20 25 40 50 64 100 150 250 15 24 30 38 60 75 96 150 225 375 Pressure Class ANSI (barg/psig) 150 300 600 900 1500 2500 Ao Carbono 30/435 78/1125 156/2250 233/3375 388/5625 647/9375 Ao Inox 30/435 75/1080 150/2160 225/3240 375/5400 625/9000

JIS
10K 21 16K 41 Pressure Class JIS (barg) 20K 30K 40K 51 78 102 63K 161

MATERIALS

19

Coating Properties
Coating Hard Chromium NiBo Stellite SF 6 Tungsten Carbide WC-Co Tungsten Chromium Carbide (W/Cr)C CrC Description Electrolytic Coating Ni-Base Alloy (S&F) Co-Base Alloy (S&F) Tungsten Carbide (HVOF) Tungsten Chromium Carbide (HVOF) Chromium Carbide (HVOF) Hardness HRC/HV 70 / 1000 55 / 600 45 / 450 70 / 1000 70 / 1000 65 / 800 Thickness mm < 0,1 0,5 - 1,0 0,5 - 1,0 0,1 - 0,2 0,1 - 0,2 0,1 - 0,2

Thermal Spray Processes: S&F HVOF Plasma

20

Spray and Fuse High Velocity Oxyfuel Plasma Spraying

Trim Valve Sliding Pairs

Ball Seat Medium Service Moderate pressure and temperature. Corrosion resistance equal to 316 Moderate pressure and temperature. Corrosion resistance equal to 316 Hard Chromium Celsit Liquid / Gas

Stellite SF 6

Celsit

Liquid

NiBo

Stellite 12

Gas up to 550 C High pressure and high temperature. Poor corrosion resistance High pressure and Gas up to 400 C moderate temperature. Poor corrosion resistance Moderate pressure and temperature. Good corrosion resistance

Tungsten Carbide WC-Co

Tungsten Carbide WC-Co

Tungsten Chromium Carbide (W/Cr)C

Tungsten Chromium Carbide (W/Cr)C

Liquid

21

Relative Resistance to Cavitation Damage

Material Stellite 6 over 316 17-4 PH 45 HRC AISI 316 Carbon Steel Brass Aluminium
22

Hours Tested 120 12 6 2,25 0,5 0,033

Index* 20 2 1 0,38 0,08 0,006

* 316 SS is the reference. The others were tested until they showed approximately the same amount of damage as did the 316 SS sample after 6 hours of testing

Seat Technology

Severe service

Solids handling Slurries Solids suspended in gas Control service High temperature designs to 1100F

Application & industry specific

Polymer Proof Chemical Severe Shock Pulp & Paper Erosion Mining Delayed Coking Refining Surge Control - LNG

23

Coatings & Surface Treatments

Hard Chrome Chrome Carbide Nickel Boron Stellite Nitride Tungsten Carbide

24

Trim Coatings

Hard Chrome (HCr)

Chrome Carbide (CrC)

Plugs Coating process Electroplated Hardness 64-69 HRC Corrosion resistance similar to 316 SS Do not use with acids Max. temp 842 F

Trims Coating process HVOF Hardness 60-65 HRC Excellent wear and and corrosion resistance Max. temp 1472 F

Cobalt based hard facing (Stellite)

Trims Coating process PTA (Plasma transferred arc welding) Hardness 36-43 HRC Resistant to adhesive wear, erosion, cavitation, and corrosion Max. temp 1112 F

Tungsten Carbide (WC-Co)

Trims Coating process HVOF Hardness 65-70 HRC Excellent wear and and corrosion resistance, especially in high cycle applications Max. temp 842 F

Nickel Boron (NiBo)

Plugs Coating process thermal spray and fuse Hardness 55-60 HRC Not suitable for corrosive liquids Used in high temp and abrasive applications Max. temp 1112 F 25

OPERATION CONCEPT

26

Operation Pneumatic Concept

Operates on a pneumatic signal from a controller Operation is based on force-balance principle Double and single acting for rotary and globe valves They accurately position the control valve assembly in response to a change in input signal The dynamic behavior can be changed by choosing different size pilot valves The direction of operation can be changed simply by reversing the builtin change over piece and the cam. External piping not be modified.

27

Operation Electro Pneumatic Concept

Operation - Digital Concept

29

FIRE SAFE CONSTRUCTION

30

10

Fire Safety - Fire Tested

Remember: Most valves do not need to be Fire Safe Fire Safety is the term used to describe a valves ability to withstand the effects of a fire acting on its outside surfaces. The basic idea being that in the event of a fire a Fire Tested valve will not add to the intensity of the fire or its dangers by leaking its flammable or dangerous contents. There are a number of very different tests applied to valves to qualify them to be described as fire tested/safe: Some only require that the test valve is burned for a short time while it is full of water and that it doesnt leak more than a certain amount to atmosphere. There are rubber lined butterfly valves that pass this test (Lloyds register). Others require that the test valve is burnt for long enough to ensure that any soft materials are completely destroyed, that it remains operable and retain some ability to shut off flow, with higher than usual seat leakage but little or no external leakage. This was the most common fire safe test based on the old BS5146. (based on the old OCMA Oil Companies Materials Association, FSV1 test) The current most recognised tests: BS6755 part 2 (Europe(France ELF)) and API 607 edition 4 (USA) which require that the valve is burned in the closed position full of water for a considerable time. The water turning to superheated steam and at high pressure in any cavities. Any external leakage is very restricted during the burning. After cooling the valve is operated a number of times and then tested for seat leakage.

31

CONTROL TECHNICAL ISSUES

32

PROCESS MODEL
i

p1

p2 q

q = Flow p = Pressure h = % opening I = Signal

p1

DPm =
p0 p p2 Qm
33

pm pf

DPf =
Qf

pm p0 p f p0

Q=

q qf

p = p1 p2

11

Recommended Velocity Limits for Liquid Service

Erosion Corrosion Stability (butterfly) Ball, Segment, Globe 33 fps (continuous) 39 fps (infrequent <10%)

Butterfly 23 fps (continuous) 27 fps (infrequent <10%)

Dead time (td)

Dead time is the the interval of time between input change and the start of output change. In valves it is caused by friction load and the compressibility of air

Input signal

Valve travel

td
35

Time

Dead band
Dead band is the range through which the setpoint signal can be varied without response from the valve (actuator). It is caused by backlash and friction. Dead band is measured by changing the setpoint slowly until the valve moves, and then changing the setpoint slowly to the other direction until the valve moves again. The dead band is the setpoint change needed to get the valve moving after the direction change.
Setpoint Dead band Setpoint change needed to get the valve moving after a change in the direction

Valve position Time

Dead Band = Stiction + Backlash

Stiction Resistance to the start of motion, to overcome static friction during signal reversal Backlash A relative movement between interacting mechanical parts, resulting from looseness, when motion is reversed

36

12

Hysteresis plus dead band

Hysteresis plus dead band is the maximum deviation between the valve positon with an increasing signal and the valve position with a decreasing signal. The measurement is made when the valve position has stabilized.

h+db
Valve travel

Time
37

Hysteresis plus dead band

Dead band
Output

Histeresis + Dead band

Histeresis

Output

Input

Input

Output

Input

Measure of the input Results from stiction and backlash

38

Cannot be measured without the effects of dead band

Measure of the output Results from the inelastic quality of the package

Linearity

Downscale curve

The maximum deviation relation to the reference line

Upscale curve

Output
Specified curve

Input
39

13

Entech Specification for Control Valves

Backlash + Stiction (= Deadband) Less than 1% Speed of Response by following table (step 2%)
Size (in) 0-2 >2-6 > 6 - 12 > 12 - 20 > 20 +
40

Entech v. 2. 1 Stroke Times Td T63 T98 (s) (s) (s) 0,1 0,3 0,7 0,2 0,6 1,4 0,4 1,2 2,8 0,6 1,8 4,2 0,8 2,4 5,6

STEP RESPONSE

Load Factor
PA PA PJ

PB

L DOUBLE =

pA pB ps

L SINGLE _ AIR =

pA pJ pS p J
=

* 100%

when p A p J

*100%
LSINGLE
_ SPRING

pA p j pj

* 100 % when p A < p J

42

14

Process variability
Process variability is the variation of process variable. SOME CALCULATION METHODS:

Variability[ % ] = x max [ % ] x min [ % ]

Variabilit y [% ] = where 2 100 X = standard deviation X = mean value
ITAE = integral time absolute error
Time

IAE = integral absolute error

43

Stem Seal Life

40 times
Globe

Stem seal leakage

Rotary

Rotary

Globe

0 1 2 3 4 5 6 7 8 9 10 Operations (thousands)

Cost
HPBF Seg. Ball Ecc. Plug Globe

$20.000

$15.000

$10.000

$5.000

$0

4 6 Size (inch) Size (inch)

10

15

WEIGHT - Flow Capacity and Compactness

To high capacity applications - Ball, Segment, Butterfly

To medium capacity applications - Ball, Segment, Butterfly, Globe, Eccentric Plug To low capacity application - Segment, Globe

Ball, segment ball, BF: flow capacity 2 x Globe

Weight
HPBF Seg. Ba ll Ecc. Plug Globe

2000

1000

500

4 6 Size (inch) Size (inch)

10

NEMA Ratings (General Purpose Areas)

Most Significant Ratings

NEMA 4 - Waterproof NEMA 4X - Waterproof & Corrosion Proof NEMA 6 - Temporary Submersibility NEMA 7 Class I (Obsolete) NEMA 9 Class II (Obsolete)

pounds

1500

16

Hazardous Area Ratings

Hazardous Area Approvals (North America)

Manufacturers May Use Ratings on Labels Even Though Non Third
Party Approved

Third Party Approval Agencies; Equipment must be Tested by Third

Party to NEC Standard to have Logo on Label:

- FM (Factory Mutual, US Market) - UL (Underwriters Labs, US Market) - ULc (UL for Canada & US Markets) - CSA (Canadian Standards Association)

Process Environment

Enclosure Standards &

Protection Concepts

17

Process Environment Enclosures

Process Environment

Hazardous Area
Descriptions

Process Environment

IEC & EU Standards

18

Process Environment Guide to Hazardous Locations

Process Environment Chemical Compatibility

FLOW CHARACTERISTIC CURVES

57

19

THEORICAL CHARACTERISTIC CURVES

1
Relative flow coefficient

0,8 0,6 0,4 0,2 0 0 0,2 0,4 0,6 0,8 1 Relative valve travel
Equal percentage Quick opening Linear

58

Real and Typical Flow Characteristic Curves

400 350 300 250

Cv

200 150 100 50 0 0 0,1 0,2 0,3 0,4 0,5 0,6 0,7 0,8 0,9 1

80 Ball valve 80 Segment valve 80 Butterfly valve 80 Globe valve

Relative valve travel (opening)

59

INSTRUMENTED AIR QUALITY

60

20

Air Quality
Air quality according to ISA S7.3 and ISO 8755 Standards: Dew point 10 Celsius degrees less than the minimum temperature registered on the region of the installation. But not too low dew point because too dry air cause wearing of pneumatic instruments, like positioners; Particle size less than 3 micra; Less than 1 ppm oil content ; No chemical contaminants
61

NOISE CAVITATION FLASHING

62

REASONS FOR NOISE

Noise is energy; Energy is coming from the moving liquid; Everything in the pipeline causes noise; In the valve there is differential pressure in a short distance - lot of energy is turned in to noise; Noise is generated mainly by the region just after the vena contracta point; The nature of the dB values is such as a small increase in dB number means big changes in human ear and in sound energy: 3 dB increase is just noticeable; 5 dB increase is clearly noticeable; 10 dB increase is twice as loud; 20 dB is much louder. Human ear - 20 to 20.000 Hz; 63 Need to consider pipe wall attenuation
dBA 130 125 95 70 65 20 0 Example Rock Band Threshold of pain Power mower (1 m) Vacuum cleaner (3 m) Cocktail party (second drink) Electric clock (at 3 a.m) Threshold of hearing

Valve Size (in) up to 3 4 to 6 8 to 14 16 or larger

Noise Limit 80 dBA 85 dBA 90 dBA 95 dBA

21

Nature of Aerodynamic Noise

When compared to the hydrodynamic noise the aerodynamic noise is not so dangerous When noise levels raise high enough the vibrations can cause some disturbance to the action of the positioner or can cause mechanical damages in the pipeline; 100 dB causes heavy vibration on the pipeline; 110 dB means very heavy vibrations, mechanical damage.

64

Aerodynamic Noise Generation

Velocity Pressure

Sudden expansion and compression

65

Valve Noise Generation

Sudden expansion and compression at vena contractaSevere turbulence Supersonic velocity downstream of vena contracta Turbulence generates sound waves Sound waves propagate down the pipe and through pipe wall

Shock waves and very severe turbulence

66

22

NOISE RADIATION
Point Source: 6 dB reduction per doupling of distance away from source ex.: voice, atmospheric venting Douplings Line Source: 3 dB per doupling ex.: long pipe, busy highway
1 2 3 4 5 6 7 8 1m 2m 4m 16 m 32 m 64 m 128 m 256 m

1m 1m

The dB values has a logarithmic scale.

67

Point to calculate the noise

Potential valve problems in gas flow

High trim and outlet velocity may cause :
68

erosion noise vibration V max < 0.5 Mach (continuous duty) V max < 0.7 Mach (infrequent duty) downstream noise is what counts gas noise can be carried significant distances in downstream piping 110 dBA may cause vibration at high noise levels the instrument may not perfom optimally 85 dBA is common limit to avoid hearing defect Never quote the valve exceeding noise level 120 dBA !

Noise is energy !

Valve Noise Reduction Strategies

Source Control - Quiet valve - Static restrictor Path Control - Distance - Heavy Wall Pipe - Thermal or Acoustic Insulation

69

23

Noise and Anti-cavitation Trim

P1

With Q - Trim P2

Q - Trim Plate

Without Q - Trim

PRESSURE DROP STAGING

FLOW DIVISION

Diffuser
Single- or Double-stage. Capacity not limited. Suitable when Dp/p1 ratio is very high Custom-made for each case.

71

15 to 20 dBA attenuation

Attenuator plate (A-plate)

Easy to mount, Cost-effective. Suitable when Dp is app. constant and
Dp/p1 rather high

Capacity is limited, since max. hole area

is about 40% of total area.

When more capacity is needed, plate

must be bigger.

Plate sizes and Cv-values have been

standardized.

A-plate together with Q-trim can achieve

up to 25 dBA attenuation.

72

24

In Line Silencer

73

Up to 50 dBA attenuation

Vent Silencer or Diffuser

Up to 50 dBA attenuation
74

15-20 dBA attenuation

Pipe Wall Effect

Relative pipe wall attenuation (db) Nominal Pipe Size 2 4 8 12 16 SCH 40 0 0 0 0 0 SCH 80 -4 -4 -4 -5 -6 SCH 160 -10 -10 -11 -12 -13

75

25

Insulation
Thickness in Inches

0 25

0.4

0.8

1.2

1.6

2.4

2.8

3.2

Noise Reduction (dBA)

20
Practical limit due to acoustic short circuits.

15
Acoustic

10
Thermal

5 0 0 10 20 30 40 50 60 70 80

76

Cavitation
When differential pressure has reached the choked flow limit (a.k.a. Terminal Pressure Drop or Allowable Pressure Drop) at vena contracta, and when downstream pressure recovers above liquid vapour pressure, cavitation is produced.
P P1
Vena contracta

P2
Cavitation

Pv vapour pressure
77

Liquid Noise Generation - Cavitation

Cavitation occurs in two stages:

Liquid boiling point depends on pressure.

Pressure at vena contracta drops below liquids boiling point, bubble formation boiling - will start without any change in temperature.. vapour bubbles implode.

Pressure after vena contracta increases, boiling stops and

7 8

26

Cavitation damages
Damaged surface is spongy and rough. Damages can be inflicted in fairly short time. Cavitation is countered mainly by staging the pressure drop.

79

Cavitation damage
P about 580 psi. Hot water 140F

80

Cavitation Damage Prediction Maximum Calculated SPL

UP TO 3 VALVE SIZE 4 TO 6 8 TO 14 16 AND LARGER 80 dBA 85 dBA 90 dBA 95 dBA

27

Anti-cavitation design-rotary valves

QLM-ball Q-trim valve

P1 One-plate Q-Trim P2 No Q-Trim

82

Fixed resistors for liquid

Baffle-plate Orifice-plate

Used to share total pressure drop between valve and plate. Works well, but only at flow rate plate is designed for.
83

Flashing
The image cannot be display ed. Your computer may not hav e enough memory to open the image, or the image may hav e been corrupted. Restart y our computer, and then open the file again. If the red x still appears, y ou may hav e to delete the image and then insert it again.

Vena contracta

pressure p1 cavitation

velocity

pv pvc flashing p2

84

28

Flashing
When differential pressure has reached the choked flow limit (a.k.a. Terminal Pressure Drop or Allowable Pressure Drop) at vena contracta, and when downstream pressure remains below liquid vapour pressure, flow is flashing.
P P1
Vena contracta

Flashing

Pv vapour pressure

P2

85

Flashing damages
Typically, damage potential of flashing is smaller than in cavitation. Damages are those or erosion type wear, smooth grooves and cavities. Flashing is tamed by material selection and by reducing downstream velocity.
86

Coping with flashing

Coping with flashing

Equipment

Pipe/process design

Hardened trim Rotary valves (flow direction, No Q-trim)

Lower temperature Use enlarged downstream piping Locate flashing valve near receiving vessel

87

29

CONTROL VALVE SIZING

88

Valve Size

Manual and automated on-off valves are mostly

the same size as the pipe.

Control valves need to be sized using the actual

working conditions to do the best job. Only rarely are they the same size as the pipe, never bigger and mostly one size smaller. Recommended not less than middle of the inlet piping diameter.

89

Liquid flow
Flow rate (q) through a valve depends primarily on Pressure differential (Dp), and Capacity (Cv).

q
90

Cv p

30

Liquid flow through an orifice (valve)

pressure p1

Vena contracta

p2

velocity
91

Gas, vapour, steam flow

Flow rate (q) through a valve depends on Pressure differential (Dp), and Capacity (Cv).

q
92

Cv p

But interrelation between pressure and flow rate is not as clear as in liquid sizing! Similarities exist at small Mach Nos. where compressibility plays a very small role.

Gas flow through a valve

pressure p1 p2 velocity

93

31

Cv
Flow Coeficient

94

Sizing parameters measurement - Cv

Done in manufacturers laboratory
Cv values - inherent characteristic curve, Noise values, pressure recovery factor (FL), Incipient cavitation pressure drop ratio (z), and Choked flow pressure drop ratio (xT).

Cv is dimensionless figure. Definition: Number of US gallons of 60 F water flowing through a valve in one minute, at one psi constant differential pressure.
95

SEVERE SERVICE APPLICATIONS

96

32

Typical valve for anti-surge application

Trunnion mounted top entry ball valve Triple excentric butterfly valves Segment valves

97

Metso valves for dirty service

Requirements
- non-clogging design - low leakage to atmosphere - rugged trim - reliability

98

Refinery Fuel Gas Applications

Heaters Furnaces Exchangers Steam Generation Power Generation

9 9

33

Fuel Gas Products

FM Supervisory Cock Valves FM Gas and Oil Shutoff Valves FM Emergency Shutoff and Firesafe Valves CSA Gas Shut off and Vent Valves

100

Dampers - Furnaces
Dampers
Variability reduction Reduction of residual O2; Economy of fuel gas; Smooth operation; Feedback position to control room

101

CONTROL VALVES

ISA Lima Peru October 2010 Jorge Souza

102

34