Jamnagar The Boss of Control Loop, Final Control Element 2 Reliance Industries Ltd. Jamnagar CONTROL VALVE AN OVERVIEW 3 CONTENT - WHAT IS A CONTROL VALVE ? CONTROL VALVE ACTUATOR STANDARDS APPLICABLE FOR CONTROL VALVE FLASHING CAVITATION CONTROL VALVE SELECTION & INTERCHANGEABILITY VALVE GLAND PACKING & MATERIAL OF CONSTRUCTION CONTROL VALVE LEAKAGE CLASS CONTROL VALVE CHARACTERISTICS ARDUOUS SERVICE VALVE NOISE REDUCTIONS PRACTICES TODAYS DISCUSSION CONTENT - WHAT IS A CONTROL VALVE ? CONTROL VALVE ACTUATOR & ACCESSORIES STANDARDS APPLICABLE FOR CONTROL VALVE FLASHING CAVITATION CONTROL VALVE SELECTION & INTERCHANGEABILITY VALVE GLAND PACKING & MATERIAL OF CONSTRUCTION CONTROL VALVE LEAKAGE CLASS CONTROL VALVE CHARACTERISTICS ARDUOUS SERVICE VALVE NOISE REDUCTIONS PRACTICES 4 WHAT IS A CONTROL VALVE ? CONTROL VALVE This is a device used to modulate flow of process fluid in line by creating a variable pressure drop in the line .
Normally the pressure drop is made with respect to the control signal received towards flow condition correction required.
5 WHAT IS VALVE FLOW COEFFICIENT ?
VALVE Cv - No. Of US gallon [ USG = 3.7 Ltrs] of water per minute passing through the valve in full open condition with 1 PSI pressure Drop across the valve at 15 deg C temp. So essentially valve Cv is capacity of valve in terms of water which helps us to identify suitable size required for any fluid in any pressure / temp. condition. VALVE Kv - Quantity of water in M3/Hr. at temperature between 5 to 40C that will flow through the valve at a specified travel with a pressure drop of 1 Bar. Kv = 0.856Cv 6 TYPE OF CONTROL VALVE Also valves may be further subdivided as shown below BY SHAPE BY INTERNAL BY CHAR. BY GUIDING GLOBE PLUG EQ% TOP SINGLE SEAT DOUBLE SEAT BUTTERFLY CAGE LINEAR CAGE ANGLE FULL BALL QUICK OPEN TOP & BOTTOM SLANT SLEEVED PARABOLIC BUSH/BEARING Y TYPE V BALL All Control valve can be divided in two category. 1. Sliding stem ( Globe valve) 2. Rotary shaft ( Quarter turn ) 7 VALVE ACTUATOR
Actuator - Mechanism which operates the valve by receiving the control signal. Type of Actuator Pneumatic - Spring Diaphragm Piston Cylinder
Electrical - Not discussed
Hydraulic- Not discussed 8 VALVE ACTUATOR
9 VALVE ACTUATOR
10 ANSI :- AMERICAN NATIONAL STANDARDS INSTITUTE B16.34 :- STEEL VALVES DEFINES CRITERIA FOR VALVE WALL THICKNESS REQUIREMENTS DEFINES PRESSURE / TEMPERATURE RATINGS DEFINE HYDRO-TEST REQUIREMENTS Example :- A351 CF8M ( Material :- 316SST; Temp range :- -425 F to 1500 F) A216 WCB ( Material :- Carbon Steel; Temp range:- -20 F to 1000 F )
B16.37 :- HYDROSTATIC TEST PROCEDURE DEFINES REQUIREMENT FOR HYDRO-TEST = 1.5 X MWP MWP = MAXIMUM WORKING PRESSURE
B16.104 :- CONTROL VALVE SEAT LEAKAGE CLASSIFICATION ESTABLISHES TEST PROCEDURES AND SEAT LEAKAGE CLASSES API :- AMERICAN PETROLEUM INSTITUTE SPEC 6B :- DEFINES PIPELINE VALVE SPEC 600 :- STEEL GAGE VALVES, FLANGED BUTT WELDING ENDS CONTROL VALVE STANDARDS 11 VALVE ACCESSORIES VALVE POSITIONERS PNEUMATIC ELECTRONEUMATIC SMART DIGITAL PROXIMITY SWITCHES INDUCTIVE TYPE PNEUMATIC CAM OPERATED SOLENOID VALVES LATCHING/ NON-LATCHING WITH MANUAL OVERRIDE SIGNAL BOOSTERS PRESSURE VOLUME SIGNAL INVERTERS HANDWHEEL AIR VOLUME TANK
12 NACE :- NATIONAL ASSOCIATION OF CORROSION ENGINEERS NACE MR-01-75 DEFINES SULFIDE STRESS CRACKING RESISTANCE MATERIAL MATERIAL COMPLY TO NACE STANDARD ARE CARBON STEEL WITH HEAT TREATMENT SST 302,304,316,17-4PH ALLOY STEEL MONEY, HASTELLOY C MATERIAL NOT SUITABLE FOR NACE ENVIRONMENT IS CAST IRON CONTROL VALVE STANDARDS 13 ISA :- INSTRUMENT SOCIETY OF AMERICA DEFINES STANDARDS FOR CONTROL INDUSTRY Example :- VALVE SIZING EQUATIONS. NOISE PREDICTION TECHNIQUE CONTROL SIGNAL 3 - 15 PSIG, 6 - 30 PSIG OSHA :- OCCUPATIONAL SAFETY AND HEALTH ACT DEFINES CRITERIA FOR PERMISSIBLE DURATION FOR EXPOSURE OF NOISE LEVEL
CONTROL VALVE STANDARDS 14 Control Valves Selection , Sizing and Specification
DEP 32.36.01.17- Gen July 1987 & Basic Process control & Instrumentation Shell M114-1999 Shell Best Practice [Ref Process Measurement and Control Devices Shell Canada Ltd Standard 16-1.2] SHELL REFERENCES 15
CONTROL VALVE LEAKAGE Control Valve Leakage -
This is basically the fluid which passes through the valve when the valve is fully closed. This value however should not be considered as the valve Cv at NIL Opening.
So this leakage shall depend on the contact of valve plug & seat with the seating force applied for holding the plug over the seat.
16
CONTROL VALVE LEAKAGE ANSI/FCI 70-2 Test Medium Pressure and temperature Class II Class III Class IV Class V Water Service DP at 10 to 52deg C Port dia. Bubbles per Min. mL per Min. 1 1 0.15 1 - 1/2 2 0.30 2 3 0.45 2 - 1/2 4 0.60 3 6 0.90 4 11 1.70 6 27 4.00 8 45 6.75 Maximum Leakage 0.5% valve capacity at full travel 0.1% valve capacity at full travel 0.01% valve capacity at full travel 0.0005ml/min/psid/in. port dia Class VI Service DP or 50 PSID whichever is lower at 10 to 52deg C Water / Air Service DP or 50 PSID whichever is lower at 10 to 52deg C Air 17 VALVE CHARACTERISTICS
Equal % - Rate of change of flow due to change of valve travel is proportional to earlier flow.
Linear - Rate of change of flow is same to rate of change of valve travel
Quick Open - Full capacity attaining without change of travel after initial opening
On/Off - Used mainly as Isolation valves (Pump suction and ESD valves) 18 1. CHARACTERISING FLOW Linear Cage Quick Opening Cage Equal Percentage Cage Modified Equal percentage flow
2. NOISE ABATEMENT
3. ANTI CAVITATION
TRIM AND CAGE DESIGN 19 CHARACTERIZING FLOW BY CAGE TYPE 20 CHARACTERIZING FLOW % Valve Travel 0 20 40 60 80 100 100 80 60 40 20 0 C v
D e s i g n
C v
%
Quick Opening 21 VALVE SELECTION PROCESS FOLLOWED IN RELIANCE
If valve sizing does not give warning of cavitation, flashing or Noise level ( >85dBA) then select standard trim valve. If valve sizing gives warning of cavitation, flashing or Noise level ( >85dBA) then select arduous service trim valve. Example:- For cavitation select CAVITROL III stage 1 to 5 valve or CAVITROL 4 valve. For noise select WHISPER I ,III or WHISPERFLO valve trim. Select the suitable Approved vendor suiting the product . Example:- ABB - Introl design or CCI - DRAG design. In case of very high DP ( DP*100/P1 > 50%) or Noise select ABB or CCI valves. Example:- Compressor Anti - surge control valves - CCI- DRAG design. 22 VALVE SELECTION PROCESS
Carbon steel WCB Carbon steel NACE Stainless steel 316 or 316L Standard Materials : ANSI rating class 150 ANSI rating class 300 ANSI rating class 600 Standard Ratings : Is it standaard material Yes No Is it standard flange rating Yes No 0 deg. C + 420 deg. C Standard Temp. Rangge Is temperature withing standard range Yes No Choke Flow Cavitation Severe Service : Noise above 85dbA Oxygen service Low temperature service HF service Ethylene oxide service Vacuum service HP steam service Hydrogen service Chlorine service Is it sever service No Yes Standard valve design and application. Ref DEP 32.36.01.17 All Section except 6 and 7 Special valve design and application ref DEP 32.36.01.17 23 POPULATION OF CONTROL VALVES AT RELIANCE JAMNAGAR.
Based on above criteria RIL complex has following Installed quantity of valve Fisher direct supply ( Through Bechtel ) :1800+ valves. Fisher package supply valves :800+ Masoneilan package supply : 180 + ABB UK direct supply :150+ CCI USA direct supply :40+ Fisher Gulde package supply : 190 + Linde Mepag package supply : 120 + Copes Vulcan package supply : 50 + Keystone Biffi direct supply : 300 + Neles Jamesbury direct supply : 630 + Rotork MOVs direct supply : 2100 + 24 VALVE INTERCHANGEABILITY
Body pressure rating and certification ( e.g. IBR ) End connection ( Ex:- Screwed or welded flange connection ) Valve Size and type. Trim Size - Cv Leakage classification Body and trim material and certification ( e.g. NACE ) Plug and cage characteristics. Actuator bench setting / spring range. Actuator action ( AFC/ AFO ) Process temperature ( For gland packing and body - trim material ) 25 Flow Path through a Control Valve - Analogy Minimum Geometrical Flow Area Streamlines Contract as Flow Approaches Restriction Vena Contracta (Minimum Flow Area) 26 Variation in Pressure and Velocity Valve Inlet Trim Exit Vena Contracta Valve Outlet Trim Inlet Velocity Variation DP Pressure Variation P 1
P 2
27 Pressure Recovery Valve Inlet Trim Exit Vena Contracta Valve Outlet Trim Inlet DP Low Recovery High Recovery 28 FLASHING Flashing : The formation of vapor bubbles in liquid flow streams at vena contracta.
As liquid passes through a restriction (vena contracta) in a control valve the liquid velocity increases and liquid pressure decreases. And if the pressure at this point falls to or below the vapor pressure of the liquid, vapor bubbles form in the flow stream. Flashing results if this pressure remains below vapor pressure of liquid.
When a liquid flashes into vapor, there is a large increase in volume. Due to increase in volume velocity will increase and hence high velocity will erode the surface.
Flashing damages can be identified by smooth polished appearance of eroded surface. Flashing damages is usually at or near seat line of the valve plug and seat ring.
Vapor pressure :- The pressure at which liquid begins to vaporize. 29 FLASHING DAMAGE ( Tag no. 241FV040 ) 30 FLASHING DAMAGE ( Tag no. 241FV040 ) 31 CAVITATION
Cavitation : The formation and subsequent collapse of vapor bubbles in liquid flow streams. As liquid passes through a restriction in a control valve the liquid velocity increases, while the liquid pressure decreases. The pressure reaches a minimum at a point called the vena contracta, and if the pressure at this point falls to or below the vapor pressure of the liquid, vapor bubbles form in the flow stream.
Downstream of the vena contracta, flow area increases, velocity de-creases, and pressure increases.
If this recovered pressure is sufficient to raise the pressure above the liquid vapor pressure, the vapor bubbles will collapse. The collapsing bubbles generate significant noise and vibration, and can mechanically attack pipe walls and valve components.
Cavitation damages can be identified by rough and pitted surface. Cavitation damage may extend to the downstream pipeline if that is where the pressure recovery occurs. Phenomenon of Cavitation is experienced in CV and PUMPS 32 CAVITATION
Valve Inlet Trim Exit Vena Contracta Valve Outlet Trim Inlet DP P 1
P 2
P V
P VC
33 CAVITATION DAMAGE 34 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 35 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.
37 CAVITATION CONTROLS :- FISHER CAVITROL DESIGN CAVITROL - 4 38 CAVITATION CONTROLS :- ABB INTROL DESIGN INTROL CAGE 39 CAVITATION CONTROLS :- CCI DRAG DESIGN CCI DRAG CAGE 40 CAVITATION CONTROLS :- CCI DRAG DESIGN 41 CAVITATION CONTROLS :- CCI DRAG DESIGN 42 CHOKED FLOW Choked flow :- Formation of vapour bubbles in the liquid flow stream cause a crowding condition at the vena contracta which tends to limit flow through the valve. If valve pressure drop is increased slightly beyond the point where bubbles begins to form, a choked flow condition is reached. With constant upstream pressure, further increase in pressure drop will not produced increased flow through the valve. 43 NOISE FUNDAMENTALS Noise :- A random mixture of sound pressure waves of various amplitudes and frequency. Which people do not like to hear. Sound Wave :- A pressure wave with a fixed frequency and amplitude traveling through a medium. Unit of Noise :- dBA ( Decibels )= 20 Log( Existing sound pressure level / 0.0002 microbars ) Source of valve noise: Mechanical Noise :- It produces high mechanical stress - fatigue failure of vibrating part. Mechanical noise can be solved by improved design to suppress vibration by good guiding and rugged construction. Vibration of valve components :- This is due to lateral movement of valve plug relative to guide surfaces. The sound level produce normally will have frequency less then 1500Hz and is describe as metallic rattling. Fluid impingement upon the movable of flexible part ( Metallic chattering ) Components resonates at its own natural frequency ( single tone 3KHz to 7KHz)
Hydrodynamic Noise :- It is due to cavitation. It is because of implosion of vapor bubbles and is relatively low. 44 NOISE FUNDAMENTALS Aerodynamic Noise :-
Highest energy component at same frequency where human ear is most sensitive. Large amount of energy converted to aerodynamic noise.
High intensity noise resulting due to turbulent flow of gas, are due to high relative velocity. This can be classified as non-periodic or random noise with occurring frequency between 1 KHz to 8 KHz. Valve pressure drop ( Main source ), Obstruction in flow path, Valve style , having more flow directional changes, Degree of turbulence varies with valve style1, Valve size. 45 PERMISSIBLE EXPOSURE DURATIONS NOISE LEVEL OSHA :- OCCUPATIONAL SAFETY AND HEALTH ACT DEFINES CRITERIA FOR PERMISSIBLE EXPOSURE DURATIONS NOISE LEVEL IN JAMNAGAR COMPLEX MAX. 85 dBA IS CONSIDERED AS A VALVE SELECTION CRITERIA.
DURATION IN HOURS PER DAY SOUND LEVEL IN DBA 8 90 6 92 4 95 3 97 2 100 1-1/2 102 1 105 1/2 110 1/4 OR LESS 115 46 NOISE CONTROL PATH TREATMENT INSULATION OF PIPE HEAVY WALLED PIPE SILENCER SOURCE TREATMENT VALVE CAGE STYLE ( TRIM ) WHISPER - I ( DP/P1 <= 0.65 ), Noise reduction up to 18 dBA. WHISPER - III ( 0.6 <= DP/P1 <= 0.99 ), Noise reduction up to 30 dBA. WHISPERFLO (NEW DESIGN), Noise reduction up to 10 dBA. BY INLINE DIFFUSER BY WHISPER DISK 47 NOISE CONTROL - SOURCE TREATMENT WHISPER - I DESIGN WHISPER - III DESIGN 48 NOISE CONTROL - SOURCE TREATMENT WHISPERFLO DESIGN BY FISHER 49 NOISE CONTROL - SOURCE TREATMENT WHISPER DISK AND IN LINE DIFFUSER DESIGN BY FISHER 50 NOISE CALCULATION SPL = SPL DP +
DSPL CG + DSPL DP/P1 + DSPL K + DSPL P2 SPL = OVERALL NOISE LEVEL IN DECIBLE ( 1 METER DOWNSTREAM OF VALVE OUTLET AND 1METER FROM THE PIPE SURFACE ) SPL DP = FUNCTION OF PRESSURE DROP ACROSS THE VALVE ( MAJOR COMPONENT )
DSPL CG = GAS SIZING COEFFICIENT ( MAJOR COMPONENT ) DSPL DP/P1 = RATIO OF PRESSURE DIFFERENTIAL TO INLET PRESSURE DSPL K = CORRECTION IN DBA FOR PIPE SIZE AND SCHEDULE DSPL P2 = DOWNSTREAM PRESSURE
SIMPLIFIED EQUATION ( WITHOUT MUCH LOSS OF ACCURACY ) : SPL = SPL DP +
DSPL CG
51 CONTROL VALVE GLAND PACKING 52 CONTROL VALVE GLAND PACKING Temp. Range Common use Suitablity for Oxygen /Oxidizing Service Packing material Description Stem friction Special consideration -73 to 232C Non-Radioactive Yes PTFE impregented composition Split rings of braided composition impregented with PTFE Low - All chemicals ( Except Molten alkali) Non radioactive No single PTFE V - Ring Solid rings of molded PTFE Low Vacuum Pressure / Vacuum No Double PTFE V - Ring Solid rings of molded PTFE Low -84 to 232C Vacuum, All chemicals ( Except molten alkali ) Yes Chesterton 324 Split rings of braided, preshrunk PTFE yarn impregented with PTFE; available with copper rings at top and bottom of packing box to meet UOP specification 6-14-0 for acid service. Low - -18 to 538C Water, Stem Petroleum products, Radiactive and Non-radiactive nuclear Yes but upto 371C Graphite/ Ribbon/Filament Ribbon style graphite rings and rings of braided graphite fibers with sacrificial zinc washer High Low chloride content ( less then 100ppm) chrome plated stem not necessary for high temperature service 371 to 649C High temperature oxidizing service Yes Ribbon - Style graphite Solid rings of ribbon-style graphite with sacrificial zinc washers High - -40 to 232C Required 2 to 4 micro inch RMS valve plug stem finish 53 VALVE MATERIAL Essentially material for the valve is valve assembly MOC. Standard material commonly used can be listed as below - Valve Body & Bonnet - As per Process Internals - As per Process . Commonly SS316 with or w/o stellite. Valve Gasket - Graphite, Metallic SS 316 or SS 316L Valve Packing - Commonly Teflon Or Graphite Fasteners - B7 or B8M Actuator Yoke - Cast Iron Actuator Spring - Spring Steel Actuator Diaphragm - Nitrile Rubber with fabric reinforcement Accessories - Commonly Aluminum. 54 TECHNOLOGY With the advent of new technology Control Valve has undergone rapid change in terms of change in Internals, Capacity Increase, Guiding, Leakage Class Improvement, Treatment of Noise And Cavitation And Finally DIGITAL.
About 30 years back control valves were only available with top guided or top & bottom guided design with asbestos packing and practically no solution available for Hi Pressure drop application leading to Noise for Gas service Or Cavitation for Liquid Service. 55 TECHNOLOGY Now a days we are also having control valve with digital technology, where valve positioner is digital in nature and able to provide PID function at the valve itself. Digital positioner can provide the following apart from acting as interface between controller and valve actuator - 1. Provide HART feedback. 2. Can couple with Foundation Fieldbus. 3. Can provide valve diagnostics. 4. Helps in Asset Management. 5. Provide lock, soft alarms and data logging facilities. 6. Can achieve split action, remote calibration etc. 56 Trouble Shooting in Control Valves. TROUBLE SHOOTING To Check Gland Packing Increase Actuator Check Vlv Guiding High Stem Friction HUNTING (At any vlv opening) Reduce dP Use Smaller Cv valve Oversizing Change Flow dir. Flow to Close flow direction HUNTING (Near to vlv close posn) INSTABILITY CYCLIC MOTION Poor Piping Increse Support Other source Find Plug guide wear & tear Replace with new At any vlv opening Increase pipe support Throtle pump discharge valve Resonance of Vibration Change plug profile Change Cv value Resonance Noise of vlv plug At specific vlv opening VIBRATION (NOISE) DULL RESPONSE NOT WORKING ACTION LEAKAGE OTHERS MALFUNCTION 57 Trouble Shooting in Control Valves. Trouble Shooting CYCLIC MOTION Dissemble & Clean Enlarge guide ring bleeder hole Provide flashing port Use jacketed vlv body Use rotary or angle type valve Slurry/sludge in vlv guide Actuator piston ring wear & tear Change Piston ring Gland pkg hardened Change gland pkg Travel Not smooth (In both dir) Change diaph. Leak in Actuator diaph. Change stem seal Use dust seal bellow Leak from Act. stem seal Travel Not smooth (In one dir) DULL RESPONSE NOT WORKING ACTION LEAKAGE OTHERS MALFUNCTION 58 Trouble Shooting CYCLIC MOTION DULL RESPONSE Trouble in air source Trouble in electric source Leakage from tubing Check comp. elec source & Main air tubing No signal & supply pr. Trouble in controller Check Controller Control sig leakage Check air tubing Act diaph air leak Change parts Positioner air leak Change bellow or diaph No signal pr. sup pr. avl AFR contamination Clean Filter Pn tubing Leakage Check Tubing (mainly air conn.) Trouble with AFR Check AFR No sup. pr. Signal pr. avl Trouble in posn pilot relay Check Act diaph air leak Change parts Posn O/P Nil Stem/guide galling / jamming Disassemble & check Foreign particle in vlv port Disassemble & check Stem Bend Change parts Trouble in Actuator Check Act Stroke Actuator not working with air sup. NOT WORKING ACTION LEAKAGE OTHERS MALFUNCTION Trouble Shooting in Control Valves. 59 Enlarge compressor capacity Exclusive compressor Too much air consumption in other line Check AFR Trouble in AFR Drift of air sup pr. Insert vol tank & restriction to air signal loop Control loop Resistance Check Controller Trouble in Controller Hunting of Sig air pr. Check posn parts friction Check posn pilot relay Positioner loop hunting Decrease dP Higher size Actuator Shift in plug reaction force Hunting of Vlv stem CYCLIC MOTION ACTION LEAKAGE OTHERS MALFUNCTION Trouble Shooting in Control Valves. 60 Remachine & Lap seat surface Change seat & plug Corrosion & erosion of vlv seating surface Change seat & seat gasket Check seat design Corrosion & erosion of seat ring thread or gasket Tack weld defect area Change vlv body Leakage thro' inner vlv body wall Valve Closed Reduce dP Increase Actuator size Too high dP Check for Foreign parts Remachine galling portion Galling on guide or port Valve not able to close Seat Leak Tighten pkg. nut Insufficient pkg nut tight Provide lub or chg pkg. Pkg Lub missing Change pkg Wear & tear of pkg Change parts or remachine Use dust seal bellows Damage of stem surface Examine part MOC Change gasket Corrosion/erosion of seat gasket surface Gland Leak LEAKAGE Change seat ring or plug Corrosion / erosion of plug or S. ring Rangeability narrowed because of control position changed OTHERS MALFUNCTION Trouble Shooting in Control Valves. 61