A PRESENTATION ON CONTROL VALVES

Control Valves
Control Valve: A power operated device, which regulates the fluid flow rate in a process control system.

IMPORTANCE OF CONTROL VALVES

The most common final control element in the process control industries is the control valve. It manipulates a flowing fluid, such as gas, steam, water, or chemical compounds, to compensate for the load disturbance Thus, keeps the regulated process variable as close as possible to the desired set point.

COMPONENTS OF A CONTROL VALVE

A control valve consists of two main sub-assemblies Valve body assembly: The main pressure boundary of
the valve that also provides the pipe connecting ends, the fluid flow passageway, and supports the seating surfaces and the valve closure member.

Actuator : An actuator is a fluid powered or electrically

powered device, which supplies force and motion to a valve closure member.

PARTS OF AN ACTUATOR

PARTS OF VALVE BODY ASSEMBLY

TYPES OF CONTROL VALVES

.
CONTROL VALVE

SLIDING-STEM
GLOBE DIAPHRAGM GATE PINCH

ROTARY

BUTTERFLY

BALL

* THRU-BORE * PARTIAL

GLOBE VALVE
Globe valve: A valve with a linear motion closure
member, one or more ports and a body distinguished by a globular shaped cavity around the port region.

Types of Globe Valve

Simple Globe Valve

Angle Valve

Three Way Globe Valve

Double Ported Globe Valve

BUTTERFLY VALVE

BALL VALVE

FLOW CHARACTERISTICS
Linear Rate of change of flow is same to rate of change of valve travel Equal% -Rate of change of flow due to change of valve travel is proportional to earlier flow Quick opening -This produces very high flow rate change ( 90%) for very small initial lifting (30%) of valve plug.

0 10 20 30 40 50 60 70 80 90 100
Valve travel %

90 80 70 60 50 40 30 20 10 00

TYPES OF CAGES

Selection of flow characteristic

Equal percentage: # For fast process # When high rangeability is required # When system dynamics are not well known Quick opening : # For On-Off control. # When max. valve capacity must be obtained quickly. Linear : # For slow process. # When more than 40% of the system pressure drop occurs across the valve. # When major process changes are a result of load changes.

PARAMETERS OF CONTROL VALVE

CONTROL VALVE FLOW COEFFICIENT (Cv)
Cv is the number of U.S. gallons per minute of water which will pass through a given flow restriction with a pressure drop of 1 psi.
Cv = Q (p) (gpm/psi) where Q = flow p= differential pressure across the valve

Eg. : A control valve which has a Cv of 12 has an effective port area in the full open position such that it passes 12gpm of water with 1 psi pressure drop.

CRITICAL FLOW FACTOR(Cf)

The critical flow factor (Cf) is effectively an index of pressure recovery in a control valve. High Cf values indicate low pressure recovery where a low Cf value is an indication of high pressure recovery.

It is to be noted that streamlined valves such as Ball valves or Butterfly valves exhibit a high degree of pressure recovery. Globe valve style, on the other hand, exhibits a much small amount of pressure recovery.

Cavitation
It is the phenomenon that occurs only in liquid service. When the fluid accelerates to pass through the narrow restriction at the vena contracta,the pr. may drop below the vapor pr. of the fluid. This causes vapor bubbles to form. As the fluid continues past the vena contracta, as the flow area expands the the pressure builds again increasing the fluid pr. above the vapor pr. This pr. recovery causes the bubble to implode. The implosion releases high amount of energy, damages the valve internals and the body. This two stage process formation of bubble and its implosion is called cavitation.The release of the energy can easily be heard as a noise in the valve or in the downstream piping.

CAVITATION DAMAGE

CAVITATION CONTROLS
SYSTEM DESIGN
1. LOCATION OF VALVE 2. CASCADING MATERIAL SELECTION HARDEN MATERIAL, LIKE 17-4 pH, 440C, 420SST HT AND 316/COLMONOY 6 / ALLOY 6

CAVITATION CONTROLS
ANTI - CAVITATION PRODUCTS
CCI DRAG DESIGN, UP TO 380 BAR PRESS. DROP. FISHER CAVITROL - III DESIGN CAVITROL - III WITH 1 STAGE- UP TO 99 BAR. CAVITROL - III 2-3 STAGES- 99 TO 207 BAR. CAVITROL -4 , ABOVE 200 BAR, SIZE LIMIT 2 TO 6. ABB INTROL DESIGN

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. The subsequent flow will be two phase consisting partly of liquid and partly vapour. Flashing leads to high flow velocities which can damage both the trims and the body (sand blasting effect).

FLASHING DAMAGE

Accessories
AFR : Air filter regulators are used to provide a clean and regulated air. Positioner : Applications on which they should be used include the following... * When the best possible control is required. * When max. loading pr.>20 psi is required. * When reversing action is necessary. * For split range operation. * For fast response.

Thank you