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Jamnagar
Jamnagar
CONTROL VALVE
AN OVERVIEW
2
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
3
NOISE REDUCTIONS PRACTICES
BY INTERNAL
GLOBE
BY CHAR.
PLUG
EQ%
BY
TOP
SINGLE SEAT
DOUBLE SEAT
BUTTERFLY
CAGE
LINEAR
CAGE
ANGLE
SLANT
SLEEVED
PARABOLIC
BUSH/BEARING
6
VALVE ACTUATOR
Type of Actuator
Pneumatic - Spring Diaphragm
Piston Cylinder
Electrical - Not discussed
Hydraulic- Not discussed
VALVE ACTUATOR
VALVE ACTUATOR
10
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
11
12
13
SHELL REFERENCES
14
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.
15
Class VI
1
1 - 1/2
2
2 - 1/2
3
4
6
8
1
2
3
4
6
11
27
45
0.15
0.30
0.45
0.60
0.90
1.70
4.00
6.75
Air
16
Service DP or 50 PSID
whichever is lower at 10 to
52deg C
VALVE CHARACTERISTICS
Equal % - Rate of change of flow due to
change of valve
travel is
proportional to earlier flow.
Linear
to rate of
travel
Quick Open
change of
On/Of
- Used mainly as Isolation valves
17
(Pump suction
and ESD valves)
18
19
CHARACTERIZING FLOW
100
Quick
Opening
Li
Cv
%
Design Cv
80
ar
e
n
60
40
20
a
Equ
l%
0
0
20
40
60
80
% Valve Travel
20
100
21
S ta n d a rd R a tin g s :
A N S I r a tin g c la s s 1 5 0
A N S I r a tin g c la s s 3 0 0
A N S I r a tin g c la s s 6 0 0
Is it
s ta n d a a r d
m a te ria l
No
Yes
Is it s ta n d a r d
fla n g e r a tin g
No
Yes
S p e c ia l v a lv e d e s ig n
a n d a p p lic a tio n
re f D E P 3 2 .3 6 .0 1 .1 7
S ta n d a rd T e m p . R a n g g e
0 deg. C
+ 420 deg. C
Is
te m p e r a tu r e
w ith in g
s ta n d a rd
ra n g e
Yes
No
S e v e re S e rv ic e :
C h o k e F lo w
C a v ita tio n
N o is e a b o v e 8 5 d b A
O x y g e n s e r v ic e
Is it s e v e r
s e r v ic e
L o w te m p e r a tu re s e r v ic e
H F s e r v ic e
E th y le n e o x id e s e r v ic e
V a c u u m s e r v ic e
H P s t e a m s e r v ic e
H y d r o g e n s e r v ic e
C h lo r in e s e r v ic e
Y es
No
S ta n d a r d v a lv e d e s ig n
a n d a p p lic a t io n .
R e f D E P 3 2 .3 6 .0 1 .1 7
A ll S e c tio n e x c e p t 6
and 7
22
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 )
24
Streamlines Contract as
Flow Approaches Restriction
25
Vena Contracta
(Minimum Flow Area)
Velocity
Variation
P2
Valve
Outlet
Valve
Trim
Inlet Trim Exit Vena
Inlet
Contracta
26
Pressure Recovery
P
Low
Recovery
High
Recovery
Valve
Outlet
Valve
Trim
Inlet Trim Exit Vena
Inlet
Contracta
27
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.
28
29
30
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.
31
Phenomenon of Cavitation is experienced in CV and PUMPS
CAVITATION
P1
P2
PV
PVC
Valve
Outlet
Valve
Trim
Inlet Trim Exit Vena
Inlet
Contracta
32
CAVITATION DAMAGE
33
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
34
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
35
CAVITROL - III
CAVITROL - III
STAGE - 2
STAGE - 3
36
CAVITROL - 4
37
INTROL CAGE
38
40
41
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.
42
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
43
3KHz to 7KHz)
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.
44
90
92
95
97
100
1-1/2
102
105
1/2
110
1/4 O R LESS
115
45
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
46
WHISPER - I DESIGN
47
49
NOISE CALCULATION
SPL = SPLP + SPLCG + SPLP/P1 + SPLK +
SPLP2
50
51
Common use
-73 to 232C
Non-Radioactive
-40 to 232C
Suitablity
for Oxygen
/Oxidizing
Service
Packing material
Description
Stem
friction
Yes
PTFE impregented
composition
No
Low
No
Low
Special
consideration
Required 2 to 4
micro inch RMS
valve plug stem
finish
-84 to 232C
-18 to 538C
High
Low chloride
content ( less then
100ppm) chrome
plated stem not
necessary for high
temperature service
371 to 649C
High temperature
oxidizing service
High
Yes
Chesterton 324
Ribbon - Style
graphite
52
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.
53
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 Cavitation54for Liquid Service.
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.
55
T R O U B L E S H O O T IN G
M A L F U N C T IO N
LEA KAG E
A C T IO N
C Y C L IC M O T IO N
IN S T A B IL IT Y
H U N T IN G
( A t a n y v lv o p e n in g )
H ig h S t e m F r ic t io n
V IB R A T IO N (N O IS E )
H U N T IN G
( N e a r t o v lv c lo s e p o s n )
O v e r s iz in g
To C heck
G la n d P a c k in g
R educe dP
In c re a s e
A c tu a to r
U s e S m a lle r
C v v a lv e
F lo w t o C lo s e
flo w d ir e c t io n
C hange
F lo w d ir .
A t a n y v lv
o p e n in g
In c re s e
S u p p o rt
O th e r
s o u rc e
F in d
P lu g g u id e
w e a r & te a r
R e p la c e
w ith n e w
56
D U LL R ES PO N SE
N O T W O R K IN G
A t s p e c ific
v lv o p e n in g
P oor
P ip in g
C h e c k V lv
G u id in g
O TH ER S
R esonance of
V ib r a t io n
R esonance
N o is e
o f v lv p lu g
In c re a s e
p ip e s u p p o r t
C hange
p lu g
p r o file
T h r o t le p u m p
d is c h a r g e
v a lv e
C hange
C v v a lu e
M A L F U N C T IO N
C Y C L IC M O T IO N
A C T IO N
LE AKA G E
O THER S
D U LL R E SPO N SE
N O T W O R K IN G
T ra v e l N o t
s m o o th
( I n b o t h d ir )
S lu r r y / s lu d g e
in v lv g u id e
A c tu a to r
p is t o n r in g
w e a r & te a r
C hange
P is t o n r in g
T ra v e l N o t
s m o o th
( I n o n e d ir )
G la n d p k g
h a rd e n e d
L e a k in
A c tu a to r
d ia p h .
C hange
g la n d p k g
C hange
d ia p h .
D is s e m b le &
C le a n
L e a k fro m
A c t. s te m
seal
C hange
s te m s e a l
U se dust
s e a l b e llo w
E n la r g e
g u id e r in g
b le e d e r h o le
P r o v id e
fla s h in g p o r t
U s e ja c k e t e d
v lv b o d y
U s e ro ta ry
o r a n g le t y p e
v a lv e
57
T r o u b le S h o o t in g
M A L F U N C T IO N
C Y C L IC M O T IO N
N o s ig n a l &
s u p p ly p r .
A C T IO N
LE AKA G E
D U LL RE SPO N S E
N O T W O R K IN G
N o s ig n a l p r .
s u p p r. a v l
O TH ER S
N o s u p . p r.
S ig n a l p r . a v l
P o s n O / P N il
A c tu a to r n o t
w o r k in g w it h
a ir s u p .
T r o u b le in
a ir s o u r c e
T r o u b le in
c o n t r o lle r
C heck
C o n t r o lle r
AFR
c o n t a m in a t io n
C le a n
F ilt e r
T r o u b le in
p o s n p ilo t
r e la y
C heck
S t e m / g u id e
g a llin g / ja m m in g
D is a s s e m b le
& check
T r o u b le in
e le c t r ic s o u r c e
C o n tr o l s ig
le a k a g e
C heck
a ir t u b in g
P n tu b in g
Leakage
C h e c k T u b in g
( m a in ly a ir
c o n n .)
A c t d ia p h
a ir le a k
C hange
p a rts
F o r e ig n p a r t ic le
in v lv p o r t
D is a s s e m b le
& check
L e a k a g e fr o m
t u b in g
A c t d ia p h
a ir le a k
C h a n g e p a r ts
T r o u b le w it h
AFR
C heck
A FR
S te m B e n d
C hange
p a rts
C heck com p.
e le c s o u r c e &
M a in a ir t u b in g
P o s it io n e r
a ir le a k
C h a n g e b e llo w
o r d ia p h
T r o u b le in
A c tu a to r
C heck
A c t S tro k e
58
M A L F U N C T IO N
LEAKAG E
A C T IO N
O TH ERS
C Y C L IC M O T IO N
D r ift o f
a ir s u p p r .
T o o m u c h a ir
c o n s u m p t io n
in o t h e r lin e
E n la r g e
c o m p re s s o r
c a p a c it y
H u n t in g o f
S ig a ir p r .
T r o u b le in
AFR
C heck A FR
C o n t r o l lo o p
R e s is t a n c e
H u n t in g o f
V lv s t e m
T r o u b le in
C o n t r o lle r
In s e rt v o l ta n k
& r e s t r ic t io n t o
a ir s ig n a l lo o p
C heck
C o n t r o lle r
E x c lu s iv e
c o m p re s s o r
59
P o s it io n e r
lo o p h u n t in g
S h ift in p lu g
r e a c t io n fo r c e
C heck posn
p a r t s fr ic t io n
D e c re a s e d P
C heck posn
p ilo t r e la y
H ig h e r s iz e
A c tu a to r
O THER S
S eat Leak
G la n d L e a k
V a lv e C lo s e d
C o r r o s io n & e r o s io n
o f v l v s e a t in g
s u r fa c e
C o r r o s io n & e r o s io n
o f s e a t r in g th r e a d
or gasket
V a lv e n o t
a b le t o c l o s e
Leakage
th r o ' in n e r
v lv b o d y w a ll
T o o h ig h d P
I n s u f f ic i e n t
p k g n u t t ig h t
G a l li n g o n
g u id e o r p o r t
R e m a c h in e & L a p
s e a t s u r fa c e
C hange seat
& seat gasket
T a c k w e ld
d e fe c t a r e a
R educe dP
C h e c k fo r
F o re ig n p a r ts
Change
s e a t & p lu g
C heck
s e a t d e s ig n
C h a n g e v lv
body
In c re a s e
A c t u a t o r s iz e
R e m a c h in e
g a l l i n g p o r t io n
T ig h te n
pkg. nut
P kg Lub
m is s in g
P r o v id e
lu b o r c h g p k g .
W e a r & te a r
of pkg
C hange
pkg
D a m a g e o f s te m
s u rfa c e
C h a n g e p a rts
o r r e m a c h in e
U se dust seal
b e l lo w s
C o r r o s io n / e r o s io n
of seat gasket
s u rfa c e
60
E x a m in e p a r t M O C
C hange gasket
R a n g e a b i li t y n a r r o w e d
because of
c o n t r o l p o s it io n
changed
C o r r o s io n / e r o s io n
o f p l u g o r S . r in g
C h a n g e s e a t r in g
o r p lu g
THANK YOU
61