1.

0 OBJECTIVES
The objectives of the experiment are:
1) To operate and demonstrate the operation of control valve plant.
2) To sketch the major equipment, instrumentation, control infrastructure and controller.
3) To organize the types of control valves.
4) To calculate the Cv of three control valve at various valve opening.
5) To combine information for experiment from multiple sources.
6) To determine and study the installed characteristics of three control valves in their
respective piping system.

2.0 SUMMARY
The experiment has been conducted in order to fulfill the objectives of the experiment.
The experiment was carried out to determine the characteristic curve of linear, equal percentage
and quick opening control valve. The control valve characteristics refer to the relationship
between the volumetric flow rate F through the valve and the valve travel or opening position m
(X-axis) as the valve is opened from its closed to various degree of opening. There are three
control valve characteristics which is quick opening, linear and equal percentage characteristics.
The plotted graph in Figure 1.2 and Figure 1.3 represent the result for this experiment. The result
still obey the theory but it is not 100% accurate due to some errors occur and problem that
actually can be prevented by some precautions. The experiment was successfully done by
controlling the selected valve for various experiments. The data has been collected and there are
6 different tables have been tabulated. The experiment is compare between the small pump and
the big pump efficiency by controlling the valve and the flowrate is been recorded. The
experiment is discussed further in discussion part to determine either it is obey the theory or not.
Some recommendation is plug out in order to make it better. Overall, the experiment is
successfully conducted and the objectives are achieved.

1
3.0 INTRODUCTION & THEORY

3.1 Introduction

Process plants consist of hundreds, or even thousands, of control loops all networked
together to produce a product to be offered for sale. Each of these control loops is designed to
keep some important process variable such as pressure, flow, level, temperature, etc. within a
required operating range to ensure the quality of the end product. Each of these loops receives
and internally creates disturbances that detrimentally affect the process variable, and interaction
from other loops in the network provides disturbances that influence the process variable.

The process consists of two tanks, T1 and T2, filled with water up to their overflow drain
levels. When water is pumped from T1 to T2, it will overflow from tank T2 back to tank T1. Any
excess water in tank T1 and T2 will overflow into the drain. There are two pumps PB and PS
where pump PB has larger flow capacity compared to pump PS. There are three parallel
pipelines PLL, PLQ or PLE.

• PLL has inherently linear control valve FCVL.

• PLL has an inherently equal % control valve FCVE.
• PLL has inherently quick opening control valve FCVQ.

The pump (PB, PS) suction valves must remain fully open at all times. The pump by pass
valves (BVS for PS, BVB for PB) must be fully opened before starting any pump. Once the
pump has started and fully verified the respective pump by pass valve must be fully closed.

2
3.2 Theory

The control valve characteristics refer to the relationship between the volumetric flow
rate F through the valve and the valve travel or opening position m (X-axis) as the valve is
opened from its closed to various degree of opening. The symbols m or Z is used to represent the
valve travel or opening, in percentage. The valve characteristic which refer to flow rate, valve
travel position relationship, if the pressure drop across, the control valve is constant. The
pressure drop across the control valve can be almost constant only if the piping pressure drop is
concentrated at the control valve and not distributed along the pipeline. This means that pipeline
must be very short in length with minimum pressure reducing devices or equipment in series
with control valves. The control valve installed characteristic refer to the relationship between
the volumetric flow rate though the valve and the valve travel or opening position m or Z, as the
valve is opened d from its closed position to various degree of opening when the pressure drop
across the valve varies. The pressure drop across the valve varies in most actual installation
influenced also by various pressure reducing devices in series with the control valve such as the
pipe length, pipe fittings and various type of valve, flow metets and process equipment.

Figure 1.1: The graph shows the curve of control valve flow characteristics.

3
4.0 RESULTS AND DISCUSSIONS

Table 1.1 : Pump PS with FCVL for Experiment 1

1 2 3 4 5 6 7 8 9 10 11
Adjust Valve Opening (Z Valve Pressure Pump
Flowrate (F) Calculate the following ratio
FIC or m) Drop (DPv) Discharge
manual Channel Blue Channel Red Channel Green Pressure 𝐅
x100% Cv/CV
Output 1 (BL) pointer 2 (RD) pointer 3 (GN) pointer PGS 𝐅𝐦𝐚𝐱(𝐋) DPv/PGS
max
MV % USGPM % % % psi % (Psig)
Fmax(L)
100.0 81 97.1 97 11.7 15 17.2 100 0.68 1.000
16.3
80.0 14.2 71 76.2 76 14.0 18 17.5 87.12 0.80 0.796
60.0 11.2 56 55.1 55 16.9 21 19.5 68.71 0.87 0.572
50.0 9.4 46 44.4 44 18.5 23 20.5 57.67 0.90 0.459
30.0 5.4 27 23.4 24 21.4 27 22.5 33.13 0.95 0.245
20.0 3.3 16 13.1 13 22.7 28 23.5 20.25 0.97 0.145
10.0 0.9 4 3.2 4 22.8 29 25.0 5.52 0.91 0.040
5.0 0.1 0 0.0 0 23.4 29.5 25.5 0.61 0.92 0.004
0.0 0.0 0 0.0 0 23.4 30 25.5 0.00 0.92 0.000

4
 Table 1.2 : Pump PS with FCVE for Experiment 1

1 2 3 4 5 6 7 8 9 10 11
Adjust Valve Opening (Z Valve Pressure Pump
Flowrate (F) Calculate the following ratio
FIC or m) Drop (DPv) Discharge
manual Channel Blue Channel Red Channel Green Pressure 𝐅
x100% Cv/CV
Output 1 (BL) pointer 2 (RD) pointer 3 (GN) pointer PGS 𝐅𝐦𝐚𝐱(𝐋) DPv/PGS
max
MV % USGPM % % % psi % (Psig)
Fmax(L)
100.0 44 91.9 92 5.1 6 7.6 100 0.67 1.000
8.9
80.0 4.5 22 72.1 72 7.9 10 9.5 50.56 0.83 0.406
60.0 2.0 10 51.1 51 8.0 10 10.5 22.47 0.76 0.179
50.0 1.2 6 41.6 42 8.3 10 11.0 13.48 0.75 0.106
30.0 0.4 2 21.6 22 8.7 11 11.5 4.49 0.76 0.034
20.0 0.3 2 11.2 12 8.8 11 11.5 3.37 0.77 0.026
10.0 0.1 0 1.6 2 8.9 11 11.5 1.12 0.77 0.009
5.0 0.0 0 1.0 1 8.9 11 11.5 0.00 0.77 0.000
0.0 0.0 0 1.0 1 8.9 11 11.5 0.00 0.77 0.000

5
 Table 1.3 : Pump PS with FCVQ for Experiment 1

1 2 3 4 5 6 7 8 9 10 11
Adjust Valve Opening (Z Valve Pressure Pump
Flowrate (F) Calculate the following ratio
FIC or m) Drop (DPv) Discharge
manual Channel Blue Channel Red Channel Green Pressure 𝐅
x100% Cv/CV
Output 1 (BL) pointer 2 (RD) pointer 3 (GN) pointer PGS 𝐅𝐦𝐚𝐱(𝐋) DPv/PGS
max
MV % USGPM % % % psi % (Psig)
Fmax(L)
100.0 54 100 100 3.8 5 7.0 100 0.54 1.000
10.9
80.0 10.9 54 81.5 81 3.9 5 7.0 100 0.56 0.987
60.0 10.7 54 58.3 58 4.0 5 7.0 98.17 0.57 0.957
50.0 10.5 52 46.7 47 4.1 5 7.0 96.33 0.59 0.927
30.0 9.1 46 25.1 25 5.0 6 7.5 83.49 0.67 0.728
20.0 6.5 32 15.5 16 6.7 8 8.5 59.63 0.79 0.449
10.0 1.2 6 7.1 8 8.3 10 11.0 11.01 0.75 0.074
5.0 0.2 1 3.5 4 8.9 11 11.5 1.83 0.77 0.012
0.0 0.0 0 2.9 3 9.0 11 11.5 0.00 0.78 0.000

6
 Table 1.4 : Pump PB with FCVL for Experiment 2

1 2 3 4 5 6 7 8 9 10 11
Adjust Valve Opening (Z Valve Pressure Pump
Flowrate (F) Calculate the following ratio
FIC or m) Drop (DPv) Discharge
manual Channel Blue Channel Red Channel Green Pressure 𝐅
x100% Cv/CV
Output 1 (BL) pointer 2 (RD) pointer 3 (GN) pointer PGB 𝐅𝐦𝐚𝐱(𝐋) DPv/PGS
max
MV % USGPM % % % psi % (Psig)
Fmax(L)
100.0 55 94.1 94 5.8 7 27 100 0.21 1.000
11.1
80.0 9.9 50 74.8 75 7.4 9 27 89.19 0.27 0.790
60.0 8.2 40 53.9 54 9.5 12 28 73.87 0.34 0.577
50.0 7.0 34 43.1 43 11.0 14 28 63.06 0.39 0.458
30.0 4.3 21 22.3 22 14.0 18 30 38.74 0.47 0.249
20.0 2.8 13 12.3 13 15.5 20 31 25.23 0.50 0.154
10.0 0.6 3 2.7 3 15.9 20 32 5.41 0.50 0.033
5.0 0.0 2 0.0 0 16.2 20 32 0.00 0.51 0.000
0.0 0.0 0 0.0 0 16.2 20 32 0.00 0.51 0.000

7
 Table 1.5 : Pump PB with FCVE for Experiment 2

1 2 3 4 5 6 7 8 9 10 11
Adjust Valve Opening (Z Valve Pressure Pump
Flowrate (F) Calculate the following ratio
FIC or m) Drop (DPv) Discharge
manual Channel Blue Channel Red Channel Green Pressure 𝐅
x100% Cv/CV
Output 1 (BL) pointer 2 (RD) pointer 3 (GN) pointer PGB 𝐅𝐦𝐚𝐱(𝐋) DPv/PGS
max
MV % USGPM % % % psi % (Psig)
Fmax(L)
100.0 51 91.9 92 6.7 8 28 100 0.24 1.000
10.2
80.0 5.7 28 71.9 72 12.5 16 29 55.88 0.43 0.409
60.0 3.0 13 52.0 52 15.4 19 30 29.41 0.51 0.194
50.0 1.7 8 42.0 42 16.0 20 31 16.67 0.52 0.108
30.0 0.7 4 21.3 22 15.9 20 32 6.86 0.50 0.045
20.0 0.5 2 11.1 12 16.3 20 32 4.90 0.51 0.031
10.0 0.1 0 1.5 2 16.1 20 32 0.98 0.50 0.006
5.0 0.0 0 1.0 1 16.5 20 32 0.00 0.52 0.000
0.0 0.0 0 1.0 1 16.0 20 32 0.00 0.50 0.000

8
 Table 1.6 : Pump PB with FCVQ for Experiment 2

1 2 3 4 5 6 7 8 9 10 11
Adjust Valve Opening (Z Valve Pressure Pump
Flowrate (F) Calculate the following ratio
FIC or m) Drop (DPv) Discharge
manual Channel Blue Channel Red Channel Green Pressure 𝐅
x100% Cv/CV
Output 1 (BL) pointer 2 (RD) pointer 3 (GN) pointer PGB 𝐅𝐦𝐚𝐱(𝐋) DPv/PGS
max
MV % USGPM % % % psi % (Psig)
Fmax(L)
100.0 60 100 100 4.5 6 27 100 0.17 1.000
11.9
80.0 11.8 59 81.4 81 4.6 6 27 99.16 0.17 0.981
60.0 11.6 58 58.2 58 4.8 6 27 97.48 0.18 0.944
50.0 11.5 58 46.6 46 5.0 6 27 96.64 0.19 0.917
30.0 10.5 52 25.0 25 6.5 8 27 88.24 0.24 0.734
20.0 8.5 42 15.6 16 9.2 12 27 71.43 0.34 0.500
10.0 2.0 10 7.3 8 16.1 20 30 16.81 0.54 0.089
5.0 0.5 2 3.8 4 16.0 20 31 4.20 0.52 0.022
0.0 0.0 0 2.8 3 16.6 20 32 0.00 0.52 0.000

9
 90

80

70

60

50
Flowrate, %

Linear
40
Equal Percentage
30 Quick Opening
20

10

0
-20 0 20 40 60 80 100 120
-10
Valve opening (Z or m), %

Figure 1.2: Control valve characteristic for Small Pump (Exp 1)

70

60

50

40
Flowrate, %

Linear
30
Equal Percentage
20 Quick Opening

10

0
-20 0 20 40 60 80 100 120
-10
Valve opening (Z or m), %

Figure 1.3: Control valve characteristic for Large Pump (Exp 2)

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 Control valves are used to control flow, pressure, temperature, and liquid level by fully or
partially opening or closing in order to received signals from controllers by compare a "setpoint"
to a "process variable" which values are provided by sensors that monitor changes in any
conditions. The opening or closing of control valves is usually done automatically by electrical,
hydraulic or pneumatic actuators. Positioners are used to control the opening or closing of the
actuator based on electric signals or pneumatic signals.
Rangeability of a flowmeter or control valve is to express its acceptable working range by
using a ratio of its maximum to minimum acceptable flowrates. The installation of rangeability
in control valve is to express the best working flow range limits of the control valve, for an
example from 5% to 95%. Outside this flow range limits, the installed valve characteristics
deviates from the desired characteristics by more than some stated tolerance.
The Figure 1.2 and Figure 1.3 show the control valve characteristic for both small pump
and large pump respectively. The figure shows the relationship between the flow rate through the
valve and opening valve as the valve travel is varied from 0 to 100%. Flow characteristic can be
stated as “inherent” flow characteristic or “installed” flow characteristic.
The experiment is conducted in order to determine the characteristic curve of linear,
equal percentage and quick opening control valve. The characteristic curve is the study of the
effect of opening on the pressure drop and flowrate. From the plotted graph, it shows the
relationship between opening valve percentage and flowrate percentage and pressure drop.
Normally, control valve characteristic can be seen as below.

Figure 1.4: Example of Control valve characteristic

11
 Emerson Process Management (2005) stated that linear control valve is designed so that
the flowrate characteristic is directly proportional to the valve opening (Z or m), at a constant
differential pressure. A linear valve is plotted by having a linear relationship between the valve
opening and the flowrate. For example, at 50% valve opening, a 50% flowrate allow 50% of the
full flow to pass. Based on the plotted graph (Figure 1.2 and Figure 1.3), the linear curve for both
graph is almost have a linear characteristics but the line is not directly proportional and have a
little bit curvy. This is because of some error happen during conducting the experiment which if
the prevention and precaution step carefully taken before or during the experiment, the result
might be accurate and as expected.
For equal percentage control valve, the equal increments of valve opening produce equal
percentage changes in existing flow. The change in flowrate is always proportional to the
flowrate just before the change in position is made for a valve plug, disc or ball position. Figure
1.2 and 1.3 shows that the change in flow rate observed with respect to travel will be relatively
small when the valve plug is near its seat and relatively high when the valve plug is nearly wide
open.
Therefore, a valve with an inherent equal percentage flow characteristic provides precise
throttling control through the lower portion of the travel range and rapidly increasing capacity as
the valve plug nears the wide open position. Valves with equal percentage flow characteristics
are used on pressure control applications, on applications where a large percentage of the
pressure drop is normally absorbed by the system itself with only a relatively small percentage
available at the control valve, and on applications where highly varying pressure drop conditions
can be expected (Suhairi, 2010).
KLM Technology Group (2010) stated that valve with quick opening flow characteristic
provides a maximum change in flow rate at low travels and small changes when the valve plug is
near maximum. The curve is basically linear through the first 40 percent of valve plug travel, and
then flattens out noticeably to indicate little increase in flow rate as travel approaches the wide
open position. The results in Figure 1.2 and Figure 1.3 obey this theory but there are some errors
occur in Figure 1.2 where for the quick opening curve, the increasing in valve opening almost
have a constant flowrate. This might be because of problem in the valve itself or maybe there are
clogging occur in the pipe which slowing down the flowrate.

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5.0 CONCLUSION & RECOMMENDATION

The experiment is conducted in order to determine the characteristic curve of linear,

equal percentage and quick opening control valve. There are three control valve characteristics
which is quick opening, linear and equal percentage characteristics. A linear characteristic is
achieved by having a linear relationship between the valve opening and the flow rate. In equal
percentage control valve, the equal increments of valve opening produce equal percentage
changes in existing flow. The change in flow rate is always proportional to the flow rate just
before the change in position is made for a valve plug, disc or ball position. Control valve with
quick opening flow characteristic provides a maximum change in flow rate at low travels and
small changes when the valve plug is near maximum. The curve is basically linear through the
first 40 percent of valve plug travel, and then flattens out noticeably to indicate little increase in
flow rate as travel approaches the wide open position. As for the control valve characteristic for
both, small pump and large pump the graph shows the relationship between the flow rate through
the valve and opening valve as the valve travel is varied from 0 to 100%. Flow characteristic can
be stated as “inherent” flow characteristic or “installed” flow characteristic. In conclusion, the
objectives of the experiment are achieved. For the recommendation, it is suggested to always use
a new water source so that there will be no residue or corrosion which prevented the water to
flow smoothly. Also, it is recommended to clear or remove the water after the experiment so that
there will be no corrosion occur which will damage the system and control valve might not
function as it is suppose to do. Lastly, it is recommended to open and close valve correctly so
that the result of the experiment will obey the theory.

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6.0 TUTORIALS

1. What is control valve CV?

Control valve is the most common final control element in the process control industries.
Control valve manipulates a flowing fluid, such as gas, steam, water or chemical compounds,
to compensate for the load disturbance and keep the regulated process variable as close as
possible to the desired set point.
Control valve assembly typically consists of the valve body, the internal trim parts, an
actuator to provide the motive power to operate the valve, and a variety of additional valve
accessories, which can include positioners, traducers, supply pressure regulators, manual
operators, snubbers or limit switches.

2. What is control valve rangebility?

Control valve rangebility is a mean of expressing its acceptable working range, by using a
ratio of its maximum to minimum acceptable (accuracy wise) flow rates.
The installed rangebility of a control is a means to express the best working flow range limits
of the control valve from 5% to 95%. Thus, the control valve rangebility also can be defined
as the ratio of its maximum controllable flow to its minimum controllable flow.

14
3. How is the control valve characteristics normally illustrated graphically?

Quick

Openi
ng
Line
ar
Equal
%

Typically there are three types of inherent flow characteristics, namely; linear, quick opening
and equal percentage.
This flow characteristic is represented graphically as figure above. The characteristics can be
classified based on the sensitivity of the rate of change of flow through the valve to the valve
stem position.

4. What is the effect of (DPv) / (DPs) on the inherent control valve characteristics?

The control valve manufacturer can only state the inherent valve characteristics, which refer to
the flow rate (F) – valve travel position (m or Z) relationship, when the pressure drop across
the control valve (DPV) is constant. Note that the pressure drop across the control valve
(DPv) can be almost constant only if the piping system pressure drop (DPs) is concentrated at
the control valve and not distributed along the pipeline. This means that the pipeline must be
of very short length with minimum pressure-reducing-devices or equipment in series with the
control valve. Such a condition rarely exist in actual installation except in the control valve
Manufacturer test facilities, where the control valve characteristics are obtained using very
short length of piping. Such ideal valve characteristics are the valve Inherent characteristics.

15
5. Compare the characteristics curves of FCVL, FCVE and FCVQ obtained in Experiment
1 with those in Experiment 2. Is the deviation from the inherent characteristics more
serious in Experiment 2 than in Experiment 1? Please comment on the DPv and DPs in
each case.

[Answer as stated in Discussion part]

6. Why is it important to know the control valve characteristics? Which is important finally
in an operating control loop, the installed or inherent valve characteristic?

The important to know the control valve characteristics are to control condition such as flow,
pressure, temperature, and liquid level by fully or partially opening and closing in response to
signal received from controllers that compare a set point to a process variable whose value is
provided by seasons that monitor changes in such conditions. Well knowledge about control
valve characteristics will help to choice the value for a particular application depends on
various factor such as the fluid flow rate, the process temperature and pressures, and whether
the fluid is corrosive or abrasive.
An important design consideration for safety is the maximum pressure and temperature of the
flowing fluid as this will dictate a safe thickness for the body material and may determine
which material can be used.
The proper inherent value characteristic is preferred to compensate for process changes to
achieve and maintain process stability.

16
7.0 REFERENCES

1. N. E. Battikha, The Condensed Handbook of Measurement and Control, ISA–The

Instrumentation, Systems and Automation Society, 3rd ed, chapter 13, page 233.

2. Robert H. Perry, Perry’s chemical engineers’ handbook,McGraw-Hill 7th edition, chapter

8,page 77.

3. Carlos A. Smith, Ph.D., P.E.; Armando B. Corripio, Ph.D., P.E., Principles and Practice of
Automatic Process Control, John Wiley & Sons, Inc., 2nd ed, chapter 5, page 200.

4. Gregory K. McMillan, Process/ Industrial Instruments and Controls Handbook, McGraw-

Hill, ,5th edition, chapter 9, page 945.

5. Fisher Controls International LLC., 2005. Control Valve Handbook. [online] Emerson
Process Management. Available at:
http://www.documentation.emersonprocess.com/groups/public/documents/book/cvh99.pdf
[Accessed 03 October 2012].

6. Suhairi, 2010. Control Valve Theory. [online] Universiti Sains Malaysia. Available at:
http://chemical.eng.usm.my/notes/SUHAIRI/notes/CONTROL%20VALVE_Theory.pdf
[Accessed 03 October 2012].

7. KLM Technology Group, 2010. CONTROL VALVE SELECTION AND SIZING

(ENGINEERING DESIGN GUIDELINE). [online] KLM Technology Group. Available at:
http://kolmetz.com/pdf/EDG/ENGINEERING_DESIGN_GUIDELINE__control_valve_re
v%208.pdf [Accessed 03 October 2012].

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