FLUOR - New Delhi

Control systems engineering

Control Valves

By KK Varma

 Inclusions

Introduction What is a Control Valve (concept)

Flow Characteristics Valve sizing coefficient

Classification
Control Valve symbols Control Valve Assembly Valve Actuator Valve Positioner

Selection criteria
Interface with other depts... Applicable codes and standard Major vendors Lastly

Exclusions

Preparation of data sheets Sizing calculations

 Introduction (why the need for valves)

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 loop is designed to keep some important process variable such as pressure, flow, level, temperature etc. within a required operation range to ensure quality of end product. Each of these loops receives and internally creates disturbances that might detrimentally affect the process.
We gather the information from sensors in field, A controller will process this info. decide what must be done to get the process back on track.

 Control valve concept OBJECTIVE: Control valve is the final control element in a system.

Control valve is a power-operated device used to manipulate the fluid (gas, steam, liquid) flow rate in a process system and keep the regulated process variable as close as possible to the desired set point. There are two basic types of control valves :
Linear Rotary

Each type of valve has its special generic features, which may, in a given situation, be either an advantage or a disadvantage

 Control valve concept OBJECTIVE:

Linear Rotary

 Control valve classification

Linear Motion

Globe Diaphragm Pinch or Clamp

Globe Angle 3-Way

Single Seated Double Seated Split body

Control Valve

Rotary Motion

Butterfly Eccentric Plug Ball

Swing Through Lined Eccentric Segmented Full V-Notch

 Control valves symbols

P&ID symbols of various control valves per ISA S5.1

 Control valves symbols ...

P&ID symbols of various valves actuator per ISA S5.1

 Control valves assembly

Control valve assembly typically consists of - the valve body, the internal trim parts, an actuator to provide the motive power to operate the valve.

Valve Actuator
Positioner Valve stem

Valve Body

 Actuator operating modes - Linear vlv.

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 Actuator operating modes - Linear vlv.

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 Actuator operating modes - Rotary vlv.

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 Valve positioner

A valve positioner is a air relay which is used between the controller output and the valve diaphragm. It assures exact positioning of the valve stem in accordance with controller output

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 Flow characteristics

The relationship between valve capacity and valve stem travel is known as the flow characteristics of the valve..

Inherent flow characteristics

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 Selection criteria

Body size and flow capacity End connections

Shutoff leakage
Actuator sizing Valve assembly material Packing selection Valve accessories Special requirement Noise calculation Quality requirement

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 Interface with other depts...

Process For sizing of valves

For process conditions

Piping For face to face dimensions For PDS envelop - (supports if required) For P&ID markup

Electrical For electrical actuator power supply (solenoid vlvs.)

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 Applicable codes and standards

ASME B16.34 - valves - flanged, threaded and welding ends ASME B1.20.1 - Pipe threads ANSI FCI 70-2 - Control valve seat leakage

ISA 71.01 - Environmental conditions for process measurement & control systems: Temperature and Humidity
ISA 75.01 - Flow equation for sizing control valves ISA 75.03 - Face to face dimensions for flanges globe-style control valve bodies ISA 75.04 - Face to face dimensions for flangeless control valves

ISA 75.17 - Control valves aerodynamic noise prediction

NEMA ICS 6 - Enclosures for Industrial controls and systems IEC 529 - Specification for degree of protection provided by enclosure NFPA 70 - National electric code

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 Major vendors
Valve Assembly

Actuators

Masoneilan Dresser Fisher Flowserve (Valtek) Tyco Instrumentation Limited

EIM Bettis Keystone Automax Rotork Limitork

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 Lastly...
There are lot of other stuff on control valve that should be looked into...
Sizing

calculations (including vendor sizing softwares, INtools)

Datasheets
Valve Valve Valve Valve Hook

Generation

Packing Accessories Details Noise Installations up

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 Over an out !

Questions?

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 Selection criteria contd.

Body size and flow capacity Select valve type Calculate Cv required Select valve/ trim size

End connections End connection type End connection rating

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 Valve sizing coefficient Cv (basics)

Valve sizing coefficient Cv is defined as the number of US gallons per minute of water that will pass through a given restriction with a pressure drop of one psi. Cv = Q (P1- P2)/G
This is basic equation for liquid calculations, in volumetric flow Where Q - flow rate in US gpm P1 - upstream pressure in psia P2 - downstream pressure in psia G - liquid specific gravity @ flowing temp.
Back
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 Selection criteria contd.

Shutoff leakage Select seat leakage Class I, II, III, IV, V, VI

Actuator type and size Spring diaphragm, Piston, Cylinder, Double acting cylinder, Hand wheel, Electric. Check either inlet pressure or maximum shutoff pressure for actuator sizing

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 Selection criteria contd.

Valve assembly material Select valve body material trim material (plug, seat, stem or shaft) guide bushing material seat construction as dictated by seat leakage

Packing material and bonnet type Packing - Standard, Teflon (asbestos/ V-rings), Graphoil, others Bonnet type - Standard (450OF or less), Extended (450OF or above/ even for cryogenic services)

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 Selection criteria contd.

Select valve accessories Positioner, Airset, I/P convertor, Solenoid valve, volume booster, limit switches, travel stop Lo-Db plates or cartridges

Special requirements
Cavitation Flashing Two phase flow

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 Selection criteria contd.

Valve noise Gas and steam noise Liquid noise (cavitation only) Noise treatment (insulation, pipe schedule, noise attenuation design within valve body, Lo-Db plate, cartridge)

Quality requirement Non destructive testing Special painting Special packing

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