Beruflich Dokumente
Kultur Dokumente
2
General Control valves.
INTRODUCTION :-
DEFINITION :-
FUNCTION :-
3
Features of Control valves.
THERE ARE FOUR FEATURES OF CONTROL VALVES :
Capacity
Rangeability
Characteristics
Pressure drop
4
Control valves and Flow Characteristics.
The relationship between control valve capacity and valve stem
travel is known as the Flow Characteristic of the control valve.
6
Equal Percentage Characteristics.
Flow Capacity increases exponentially with valve trim travel .Equal
increment of valve travel produce equal percentage change in
existing Cv.
Equal Percentage valve plug shall be used where only small
percentage of system drop is available in Control valve.
7
Quick Opening Characteristics.
Provides large changes in flow for very small changes in lift or in
which a maximum Cv is achieved with minimal closure member travel.
It has too high valve gain.
Quick opening valve are usually specified for ON-OFF Service such
as sequential operation in either batch or semi continuous process
and in self actuated control valve .
When maximum valve capacity must be obtain quickly.
8
Cavitation.
Cavitation is condition that occurs in liquid flow where the internal
pressure of liquid at set point falls below vapour pressure and vapour
bubbles form and at downstream rises above vapour pressure again.
As this pressure recovers so that bubbles collapse and cavitation take
place.
It is possible to predict where cavitation will occur by looking pressure
condition and valve recovery factor.( sigma Method )
Cavitation sounds like stone passing through the valve.
PRESSURE PROFILE ACROSS
P SINGLE SEATED CONTROL
VALVE
P
Pv
Bubble collapse
Bubble form
Vena Contracta
9
Effect of Cavitation.
10
Flashing.
Flashing is condition that occurs with liquid flow where the Pressure fails
below it . There are then two phases flowing ( i.e. Liquid and vapour )
down stream.
Several damage can occur inside a valve due to erosion caused by the
impact of liquid droplet traveling at high speed.
Pv
Bubble form
P2 Bubble continue
down stream
Vena Contracta
11
Effect of Flashing.
12
Velocity Profile across Single seated Valve.
P1 PRESSURE PROFILE ACROSS
SINGLE SEATED CONTROL
VALVE
Pv
P2
V2
V 1(Liquid) (Liquid)
13
Piping Influence/Reynolds Number/Choked Flow.
14
Globe Control Valve Construction. .
General Control Valve Classification.
19
General Types of Control Valve.
CONTROL VALVE TYPES
Control:- Linear & equal % Control:- Quick opening Control:- Linear & equal %
Use:- Throttling Service, And linear. Uses:- Fully open / closed or
Flow Regulation, Frequent Uses:- Fully open / closed Throttling services, Frequent
Operation limited-throttling Operation, Minimal fluid
Application:- Liquid, Vapour, Application:- Most liquids Trapping in line.
Gases, Corrosive Substances High temperature, slurries Application:-Liquids, gases,
Slurries. Advantage:- High capacity Slurries, Liquids with
Advantage: Efficient throttling Low leakage and Maint. suspended Solids.
Available in multiple ports. Tight sealing with low torque Advantage :- High Capacity
Accurate Flow control. Disadvantage:- poor Good flow control, Low Press.
Disadvantage: High pressure Throttling characteristics Drop, Low cost and Maint.
Drop, more expensive. Prone to Cavitation Disadvantage:- High torque
Required for control
Prone to cavitation at lower
ECENTRIC PLUG / CAMFLEX DIAPHRAGM KNIFE GATE
Flows.
20
Eccentric Plug / Camflex Valve Construction.
21
Eccentric Disk/Ball/Knife Valve Construction
Eccentric Disk Valve V-Notch Ball Valve Knife Gate Valve
22
Butterfly/Angle/Three Way Valve Construction
Diaphrgm Type Valve Construction.
24
General Types of Actuators .
Actuator is the part of the valve that responds to the applied signal and
causes modification of the fluid flow through stem & plug.
TYPES OF ACTUATORS:
1) Diaphragm Actuator
Direct Acting
Reverse Acting
Size depends on output thrust required and supply air pressure
available.
2) Piston Actuator
Use of high pressure air to 150 psig., eliminating the need of pressure
regulator.
Used where High & Fast Stroking Speed is required.
3) Electro hydraulic Actuator:
Electro-hydraulic Actuator is single unit contains Hydraulic Pump
and Reservoir & Electric Motor.
Ideal for isolated locations
4) Manual Actuator
Used where no auto control is required
25
Direct Acting Actuators .
Actuators Fail-Safe Requirements.
Fail Safe is the action of the actuator by which the valve CLOSES (FC)
or OPENS (FO) fully in case of air supply failure.
General Types of Bonnet & Accessories .
Bonnet -
Bonnet is a part of the valve body assembly through which the valve
plug stem or rotary shaft moves.
Types Of Bonnets
Plain or Std Bonnet :-Operating Temp below 2000 c.
Finned Bonnet :- Operating Temp above 2000 c or Equal.
Extension Bonnet :- Operating Temp below 00 c or Equal.
Extension Bonnet :- Operating Temp above 4500 c.
Bellow Seal Bonnet :- where no stem leakage is tolerated For Toxic,
Expensive Fluids.
Std./ plain
Bonnet
Control valves Characteristics.
PROCESS APPLICATION INHERANT
CHARACTERISTICS
PRESSURE LIQUIDS EQUAL %
GAS (LOW FLOWS ) EQUAL %
GAS (LARGE FLOWS)
Pmax/pmin < 5 LINEAR
Pmax/pmin > 5 EQUAL %
Temperature Liquids & Gases EQUAL %
PROCESS INTERFACE
Process to provide process data to Instrument for specifying the
valve
Instrument to provide selected valve size to Process
for incorporating in P&IDs
Instrument to provide instrument air consumption figures for the
valves to Process to decide air line & header sizes.
PIPING INTERFACE
Instrument to provide Face to Face Dimensions, End Connection
Size & Rating, Actuator Height & Orientation, Envelope
Dimensions (for 3-D Model), Weight, etc.
Piping to provide location of control valves to Instrument for
deciding instrument air manifolds.
Piping to provide Pipe Material Specification to Instrument for
specifying the valves.
31
Control valves Body Material.
Frequently Used Valve Body Cast Materials Are:
CARBON STEEL (ASTM A216 GR WCC) up to 4270 C
CHROME MOLY STEEL (ASTM A217 GR WC9) up to 5930 C
CARBON MOLY STEEL (ASTM A217 GR C5) up to 5930 C
304L STAINLESS STEEL (ASTM A351 GR CF3) up to 8160 C
316 STAINLESS STEEL (ASTM A351 GR CF8M) up to 8160 C
CAST IRON (ASTM A126) up to 2320 C
32
Control valves Trim Material.
33
Control valves Codes and Standards.
ANSI B 16.34 :
Covers Pressure, Temperature rating, Dimensions, Materials, NDT
Requirements
ANSI B 16.5 :
Covers design of flanges and flanged fittings
MSS SP 67 :
Covers design and test performance requirements of Butterfly valves and
divides in to three leak classes.
ANSI B 16.10:
Face to Face dimensions
ANSI B 16.37:
Hydrostatic testing
LEAKAGE RATES AS PER ANSI/FCI 70-2
Formerly (ANSI B 16.104) for seat leak classes and testing procedures
- FCI
34
Vendor Design Documents- Sizing & Selection
Step # 1:- Define the system
Example :- The system is pumping water from one tank to another through a
piping system total pressure drop is 150psi.The fluid is water at 700F. Design
(maximum) flow of 150 gpm, operating flow rate of 110 gpm, and minimum flow
rate of 25gpm. Pipe diameter is 3 inches. At 700F, water has a specific gravity of1.0
Key Variables:- Total pressure drop , design flow ,operating flow, minimum flow
diameter, specific gravity.
Step # 2:- Define Max. Allowable Pressure Drop For The Valve
When defining the allowable pressure drop across the valve, you should first
investigate the pump. What is its maximum available head? Remember that the
system pressure drop is limited by the pump. Essentially the Net Positive Suction
Head Available (NPSHA) minus the Net Positive Suction Head Required (NPSHR)
is the maximum available pressure drop for the valve to use and this must not be
exceeded or another pump will be needed. The usual rule of thumb is that a valve
should be designed to use 10-15% of the total pressure drop or 10 psi, whichever
is greater.
For above example step#1 system, 10% of the total pressure drop is 15 psi which
is what we'll use as our allowable pressure drop when the valve is wide open (the
pump is our system is easily capable of the additional pressure drop).
35
STEP #3: Calculate the valve characteristic
Step#4:-Preliminary Valve Selection
The Cv value should be used as a guide in the valve selection, not a hard
and fast rule. Some other considerations are:
a. Never use a valve that is less than half the pipe size
b. Avoid using the lower 10% and upper 20% of the valve stroke. The
valve is much easier to control in the 10-80% stroke range.
Before a valve can be selected, we have to decide what type of valve will
be used . For our case, we'll assume we're using an equal percentage,
globe valve . The valve chart for this type of valve is shown below. This
is a typical chart that will be supplied by the manufacturer.
For our case, it appears the 2 inch valve will work well for our Cv value at
about 80-85% of the stroke range. Notice that we're not trying to squeeze
our Cv into the 1 1/2 valve which would need to be at 100% stroke to
handle our maximum flow.
Step# 5:-Check Cv & Stroke % at Min. Flow
If the stroke percentage falls below 10% at our minimum flow, a smaller
valve may have to be used in some cases.
Judgments plays role in many cases. For example, is your system more
likely to operate closer to the maximum flowrates more often than the
minimum flowrates?
Or is it more likely to operate near the minimum flow rate for extended
periods of time. It's difficult to find the perfect valve, but you should find
one that operates well most of the time. Let's check the valve we've
selected for our system:
Step#6:Check Gain across Applicable Flow Rates
Gain is defined as: