Control Valve

Session 6 - Agenda
Activity Est. Time

1. Agenda
2. Introduction to Control Valves and Regulators (Chapter 11)
3. Component Purpose and Operation, operating scenarios
BREAK
6. Class activity and HWAs
Instrumentation I - Session 06
Chapter 11
Control Valves and Regulators
Chapter 11 – Objectives (Page 1)
1. Given a drawing or actual device, identify the main

components of a control valve:
 body
 bonnet
 disc
 actuator
 stem
 seat
 spring
 valve positioner
 handwheel
 I/P transducer
2. Given a drawing or actual device, identify and describe
the following:
 current to pneumatic transducer
 indications of a sticking control valve.
3. Define terms associated with valves and other final

control elements:
 “air to close” (fail open)
 “air to open” (fail closed)
 fail last/in place/as is
4. Describe operating scenarios in which fail open, fail
closed, and fail last positions are desirable.
5. Discuss the purpose of diaphragm valve actuators and
piston valve actuators.
6. Compare and contrast a spring and diaphragm actuator
to a cylinder actuator.
7. Explain why the action of a valve actuator may not
correspond with the action of the valve.
8. Describe a valve positioner and explain three of its

uses.
9. Explain the function of each of the three gauges located
on a pneumatic valve positioner.
10. Given a pressure indication for each of the three
gauges on a valve positioner, predict what the control
valve movement will be.
11. Describe two ways a controller’s output signal can be
reversed at the valve so the valve’s action is opposite
of the controller output signal.
12. Describe a control scheme that utilizes reversing a
controller’s output signal at the valve.
13. Explain how reversing a controller’s output signal at
the valve affects the valve’s fail safe position upon
loss of air.
14. Explain the purpose and operation of the following:

 globe valves
 three-way valve
 butterfly valves
15. Given a drawing, picture, or actual device, identify
and describe pressure regulators.
16. Define the following terms associated with regulators:
 back pressure regulator (self-actuated)
 pressure reducing regulator
17. Given a Process Flow Diagram and/or P&ID, locate
and identify pressure regulators used in process
control.
18. Given an instrument air pressure regulator, perform
the following tasks:
 blow down regulator to check for condensate or oil
 set specific pressure for operating final control element.
Control Valve Key Components
 Control valves operate the

process by producing a
differential pressure drop
across the valve.
 A control valve has an

actuating device or
actuator. The actuator
provides motion to a valve
for controlling process.
 This motion drives the flow

controlling mechanism
(e.g., plug or disc)
 The body is the housing
component.
 The valve bonnet is the top
portion of the valve body
and connects the valve
body to the actuator.
 The valve plug assembly that
includes the valve stem moves to
open or close the flow path
through the valve.
 The actuator is the device that
provides motion to the valve
using a spring diaphragm, spring
piston, or double acting piston.
 The stem is the pushing and
pulling rod that transfers the
motion of the actuator to the
valve plug.(page 170)
 The seat in a valve is the
stationary part of the valve trim
connected to the body that
comes in contact with the valve
plug. When the plug is fully
seated, the flow stops.
 The spring provides the energy to
move the valve in the opposite
direction of the diaphragm
loading motion to its fail-safe
condition.
 The diaphragm is the flexible
member that creates a force to
move the stem.
 A valve positioner is actually a
proportional – only controller.
 The position of the valve stem is
sensed by a mechanical link that is
directly connected to the positioner.
 A handwheel is an actuator
accessory that is used to manually
override the actuator or to limit its
motion.
 An I/P or current to pneumatic
transducer is a device that converts a
milliampere signal into a pneumatic
pressure.
 The most common use for an I/P
transducer is to provide the source of
energy needed to drive a diaphragm
or piston actuator.
 A current to pneumatic transducer
typically receives a 4-20 mA current
signal and converts it to a 3-15 psig
pneumatic signal. Instrumentation I - Session 06
Fail Conditions
 Control valves are

responsible for
regulating the
movement of fluids in
a process.
 If there is a power or
air failure, they
should move to a safe
position.
Fail Conditions
 If a plant loses power or air supply,

the design engineers must
recognize the required fail safe
conditions during the design phase
of a plant and choose each control
valve response accordingly.
 When an air to open control valve
loses its instrument air signal or
supply, the valve fails closed
because a return spring provides
more opposing force than the
decreasing instrument air applied
to the diaphragm.
 Preventing overflowing a tank is a
good example for this case.
Fail Conditions
 If a plant loses power or air
supply, the valve fails open
because the return spring
provides more opposing force
than the diminishing
instrument air applied to the
diaphragm and the force
applied by the process.
 Failing a pressure relief valve
on a reactor in these
conditions should be fail in
the open position preventing a
pressure buildup that may
rupture the vessel.
Fail Conditions
 Actuators without a
spring or other return
mechanism usually fail
in their last position just
prior to loss of power
unless the process
pressure is high enough
to change the valve
position
Actuator Operation
Figure 11-5
Actuator Operation
Spring and Diaphragm Actuator
 Very common
 Low cost
 High mechanical
advantage
Piston Type Actuator
 Can accept much higher input
pressures
 Single acting:
- spring opposed
the piston is opposed by a
spring
- the air cushion type
has a pressure trapped under
the piston and the air
compresses as the piston is
pushed down. Then, as the
instrument signal is reduced,
the trapped compressed air
pushes the piston back up Instrumentation I - Session 06
Piston Type Actuator
 Double acting:
- the instrument air pressure is
routed to both sides of the piston
Valve Positioners
 The function of a
positioner is to make
the valve position
match the controller
output signal.
 The valve positioner
manages the moving
parts of a valve based
on the instrument
signal received from
the controller in
different ways.
Valve Positioners
o Position the valve:
Adjust the position
when the output
controller signal is
increasing or
decreasing)
o Reverse the action:
For example,
increasing the output
pressure when the
instrument controller
signal is decreasing.
Valve Positioners
o Mimic a valve trim type
(plug and seat) if output
signal characteristics are
changed by old style
curves or new style
programmed online
methods, the valve
positioner will imitate
these changes
 See page 175
Valve Positioner Operation
 Pneumatic valve positioners
on spring and diaphragm
actuators may have three
gauges:
 Instrument Pressure Gauge
or input gauge:
(the output signal from
controller or I/P transducer)
 Output Gauge:
(the pressure applied to the
actuator and can read the
pressure required for the
valve position.
Valve Positioner Operation
 Supply pressure gauge:

indicates instrument air
supply pressure.
Output Signals
 In some process control

applications the output of
the controller may need
to be reversed at the
control valve.
 This can be accomplished
by configuring the current
to pneumatic transducer
or the valve positioner to
respond in reverse to the
signal from the controller
Globe Control Valve
 Has a globular shape
appearance
 Controls the flow with its
plug and seat (trim) located
inside the inner cavity (port)
 A valve port is the orifice in
a valve defined by the
diameter of the seat.
 Double ported valves can
balance the high differential
pressure acting on the single
port valves and they have a
higher flow capacity than a
single port valves.
Globe Control Valve
Globe valve
http://www.ctgclean.com/
Three-Way Control Valve
 Is a type of globe body

valve
 It has a three connecting
ports instead of two
 They either mix two
flowing streams together
or divert one flowing
stream between two
output ports
What is going on here?
Butterfly Control Valve
Butterfly Control Valve
 Also called rotary valves
 Equipped with piston type actuators or spring and
diaphragm actuators
 Lower manufacturing costs and higher flow
capacities than globe valves
 The rotary stem has less wear on the packing than
the sliding stem
 Actuators used with butterfly valves use a rotary
motor.
 Non linear relationship between the % opening and
the rate of flow through the opening
Ball or segmented ball control valves
 Is a rotary valve that contains a spherical plug

 The control valve actuator rotates the plug to
control the flow of fluid through the valve
body
 Convenient for slurries
 Page 179
Regulators
 Are self contained and self actuating
controlling device used to regulate variables
such as pressure, flow, level, and
temperature in a process
 The important parts are:
- inlet: supplies pressure from a source
- outlet: regulates pressure
- diaphragm: senses the pressure on the
outlet side of the regulator
- pilot valve assembly: working part of the
regulator; entire mechanism works to
both supply pressure or relieve pressure
from outlet side
Regulators
An instrument air regulator action follows this
sequence:
1. The handwheel is turned
2. The spring compresses
3. The diaphragm is pushed down
4. The pen and plug move from their seat
5. Air rushes in increasing downstream

pressure (downstream of the regulator)
6. The output gauge responds accordingly
7. Equilibrium is established
Regulators
 https://www.youtube.com/watch?v=
Kf3xc1BGYGo
Backpressure Regulators
 A back-pressure
regulator is a device
used to regulate and
control the pressure of a
process fluid upstream
of the location of the
regulator.
 maintain the pressure in
the vapor space of a
vessel
Symbols for Back Pressure Regulator
Pressure Reducing Regulators
Pressure Reducing Regulators
 Control the pressure of a process fluid

downstream of the location of the regulator
 When steam leaves a boiler and could

potentially have hundreds of pounds of pressure
that need to be reduced to specific unit
requirements that may only be 150 psi.
Symbols for Pressure Reducing Regulator
for next week:
 Please review chapters 10 and 11 and

be ready for some review questions for
our class activities
 We will have a review for the whole
chapters

Control Valve

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Session 6 - Agenda

Activity Est. Time

1. Given a drawing or actual device, identify the main

3. Define terms associated with valves and other final

8. Describe a valve positioner and explain three of its

14. Explain the purpose and operation of the following:

 Control valves operate the

 A control valve has an

 This motion drives the flow

 Control valves are

 If a plant loses power or air supply,

 Supply pressure gauge:

 In some process control

 Is a type of globe body

 Is a rotary valve that contains a spherical plug

2. The spring compresses

3. The diaphragm is pushed down

4. The pen and plug move from their seat

5. Air rushes in increasing downstream

 Control the pressure of a process fluid

 When steam leaves a boiler and could

 Please review chapters 10 and 11 and

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