Process Industrial
Instrumentation and Control
Trainer
Aatif Khalid Alvi
Instrumentation Engineer
[email protected]Ph#+92-3225131504
http://pk.linkedin.com/in/aatifalvi
Training Given by:> Aatif Alvi (03225131504)
CONTROL VALVES
Training Given by:> Aatif Alvi(03225131504)
Contents
1. Introduction
2. Types
3. Components
4. Accessories
5. Maintenance
Training Given by:> Aatif
Alvi(03225131504)
Control Valve Definition
ISA DEFINITION
A POWER OPERATED DEVICE THAT MODULATES THE FLUID FLOW
RATE IN A PROCESS CONTROL SYSTEM.
A VARIABLE ORIFICE.
MAJOR
VALVE
COMPONENT
BODY
ACTUATOR
Training Given by:> Aatif Alvi(03225131504)
Control Valves
- Final Control Element in the loop
Control Valve engineering includes its
proper sizing, type of the body
selection, Actuator sizing, mode of
operation
Training Given by:> Aatif Alvi(03225131504)
Control Valve History
The first Control Valve was invented to control the steam
pressure to steam engine
Fisher holds the flag of introducing the first pressure governor
later proceed to control Valve invention
Training Given by:> Aatif Alvi(03225131504)
General Categories of Control Valve
There are two basic types of Control Valves , Sliding Stem
(globe) and Rotary (ball, butterfly) which are further divided
into sub categories
The two terminologies used NPS (nominal pipe size) usually
expressed in inches
DN nominal (nominal diameter)
Training Given by:> Aatif Alvi(03225131504)
Control Valve Assembly
ACTUATOR
CONTROL
VALVE
VALVE BODY
ASSEMBLY
BONNET
BODY
Training Given by:> Aatif Alvi(03225131504)
Basic Principle
OPEN
CLOSE
Control Valve
Operation
Outlet Pressure
Inlet Pressure
MINIMUM
CONTROLLED
MAXIMUM
Training Given by:> Aatif Alvi(03225131504)
Manually Temperature Control
Without Instrumentation
Training Given by:> Aatif Alvi(03225131504)
Automatic Temperature Control
With Full Instrumentation
Training Given by:> Aatif Alvi(03225131504)
Main components of Control valve
Control
Valve
Actuator
Valve Body
Accessories
Training Given by:> Aatif
Alvi(03225131504)
VALVE ACTUATORS
Training Given by:> Aatif Alvi(03225131504)
Control Valve Actuator Functions
Device that moves the control valve closure member .
Functions of actuator
Provide required Travel
Provide required Stroking Time
Provide Adequate Seat Load For Desired
Shutoff Fail Mode
Fail-Open
Fail-Closed
Lock-In-Last-Position
Training Given by:> Aatif
Alvi(03225131504)
Main Components of Actuator
Actuator
Power
Chamber
Yoke
Training Given by:> Aatif
Alvi(03225131504)
Actuator Family
Actuator
Types
Pneumatic
Hydraulic
Electric
Manual
Training Given by:> Aatif
Alvi(03225131504)
Control Valves Actuator
Family
Actuator Types
Pneumatic
Hydraulic
Diaphragm
Piston
Solenoid Operated
Motor Operated
Single acting
Double acting
Electric
Single Acting
Load Return
Piston
Spring Return
Single acting
Double Acting
Double acting
Rack & Pinion
Training Given by:> Aatif Alvi(03225131504)
Manual
Pneumatic Actuator
Piston
Diaphragm
Training Given by:> Aatif Alvi(03225131504)
Diaphragm Actuators
Direct Action
Reverse Action
Single Acting
Double Acting
Training Given by:> Aatif
Alvi(03225131504)
Family Of Accessories
Actuator
Accessories
Regulator
Positioner
Limit
Switch
SOV
Training Given by:> Aatif
Alvi(03225131504)
Relay
Diaphragm Actuator Sliding Stem Typ
Training Given by:> Aatif Alvi(03225131504)
Actuator Action
Direct Action
Training Given by:> Aatif Alvi(03225131504)
Reveres Action
Fail Mode Basis for Selecting an Actuator Action
DTC: Push down to close
DTO: Push down to Open
Training Given by:> Aatif Alvi(03225131504)
Piston Operated Actuator
Training Given by:> Aatif Alvi(03225131504)
Pneumatic Actuator
Training Given by:> Aatif Alvi(03225131504)
Piston Actuators
Sliding Stem
Rotary Shaft
Direct Action
Reverse Action
Single Acting
Double Acting
Training Given by:> Aatif Alvi(03225131504)
Sliding Stem Valves
The most used type is the globe valves
Available from size NPS to 4 and DN 15-DN 100
Pressure ratings are up to class 2500
Best suited for throttling applications for pressure and flow
They are best suited for high temperature, areas with piping
stress, vibrations occur
Body material includes bronze, cast iron, stainless Steel
Applications include water, oil and gas , liquids
Training Given by:> Aatif Alvi(03225131504)
Sliding Stem valves
Training Given by:> Aatif Alvi(03225131504)
Sliding Stem Valves
Training Given by:> Aatif Alvi(03225131504)
Sliding Stem Valves
Training Given by:> Aatif Alvi(03225131504)
Sliding Stem Valves
Training Given by:> Aatif Alvi(03225131504)
Ball Valves
Available ranges up DN 600, NPS 24
Best suited for on-off applications
Pressure rating class up to class 900
Not suited for throttling applications
Prize normally low than globe valves
Training Given by:> Aatif Alvi(03225131504)
Training Given by:> Aatif Alvi(03225131504)
Training Given by:> Aatif Alvi(03225131504)
Rotary Valves
Rotary valves further classified as
Eccentric Plug Valves
Butterfly valves
Eccentric valves have the combine features of sliding stem
valves (globe valves) and rotary valves on-off applications
They are available in sizes DN200, NPS8 and with class 600
and PN100
Training Given by:> Aatif Alvi(03225131504)
Training Given by:> Aatif Alvi(03225131504)
Rotary Valves
Butterfly Valves :
Butterfly valves are further divided into swing through, lined
and high performance
Most used design is swing through such valves are used for
throttling applications with shut off capability upto 1%
Pressure ratings class up to to class2500
The body material is made of PTFE ployterafluro ethelyne and
elastomers
Sizes available from DN 50 to DN1800
Training Given by:> Aatif Alvi(03225131504)
Training Given by:> Aatif Alvi(03225131504)
Training Given by:> Aatif Alvi(03225131504)
Single Acting Reverse-Action & Double acting Actuator
Training Given by:> Aatif Alvi(03225131504)
Control Actuator for high Power applications
Training Given by:> Aatif Alvi(03225131504)
Electrical Actuators
Training Given by:> Aatif Alvi(03225131504)
Electrical Actuator
Training Given by:> Aatif Alvi(03225131504)
Heavy Duty SOV
Training Given by:> Aatif Alvi(03225131504)
Motor Operated Actuator
Training Given by:> Aatif Alvi(03225131504)
Motor Operated Valve (MOV)
Training Given by:> Aatif Alvi(03225131504)
Manual Actuators
Training Given by:> Aatif Alvi(03225131504)
Manual Actuator
Training Given by:> Aatif Alvi(03225131504)
Manual Actuators
Training Given by:> Aatif Alvi(03225131504)
Gate Valve with Top Mounted Manual
Actuator
Training Given by:> Aatif Alvi(03225131504)
Side Mounted Manual Actuator
Training Given by:> Aatif Alvi(03225131504)
Control Valve Technology
Gasket & Packing
Training Given by:> Aatif Alvi(03225131504)
Packing
Training Given by:> Aatif Alvi(03225131504)
Contents
1. Packing Box In Bonnet
2. Packing Box Assembly
3. Packing Material
4. Teflon / PTFE
5. Graphite / Graphite cord
6. Asbestos
7. Grafoil
8. Inert Gas as Packing
9. Cutting & making Rings
Training Given by:> Aatif Alvi(03225131504)
PACKING BOX IN BONNET
VALVE PLUG STEM
BONNET GASKET
PACKING FLANGE
SPIRAL WOUND GASKET
ACTUATOR YOKE LOCKNUT
PACKING
PACKING BOX
BONNET
CAGE GASKET
VALVE PLUG
CAGE
SEAT RING GASKET
SEAT RING
VALVE BODY
Major Components of Typical Sliding-Stem Control Valve Assemblies
Training Given by:> Aatif Alvi(03225131504)
Packing Box Assembly
The purpose of the packing box assembly is to contain an
elastic means for preventing the leakage of a process fluid.
Suitable adjustments should be provided for varying the
compression of the packing material against the surface of
the stem.
The ideal packing material should be elastic and easily de
formable.
In addition, the packing should be as chemically inert as
possible
Should be able to withstand high pressures and high
temperatures.
Selection must be made from a variety of materials to suit the
specific service conditions.
Training Given by:> Aatif Alvi(03225131504)
Packing Box Assembly
The assembly consists of a: Packing flange
Packing follower (Bush)
Lantern ring
A number of equally spaced packing
rings.
The lantern ring provides a space for the
insertion of lubricating grease though an
isolating valve.
Training Given by:> Aatif Alvi(03225131504)
Packing Material
LOCATION OF SACRIFICIAL ZINC WASHER, IF USED.
Comprehensive Packing Material Arrangements for Globe-Style Valve Bodies
Training Given by:> Aatif Alvi(03225131504)
Packing Material
Teflon (PTFE) / Teflon Cord
Graphite / Graphite cord
Asbestos (Now a days it is not being used)
Grafoil
Inert Gas as Packing
Training Given by:> Aatif Alvi(03225131504)
Teflon / PTFE
The most popular valve packing
material is Teflon.
Because of its excellent chemical
inertness and its good
lubricating properties.
Teflon can be used in solidmolded or turned form (rings).
Solid rings should be springloaded to provide a minimum
initial pressure against the stem.
It can be used below 250C.
Training Given by:> Aatif Alvi(03225131504)
Braided Asbestos
Braided asbestos is still a popular packing material (even
prohibited to use).
It can be made as split rings.
Which can be wrapped around the valve stem.
This type of packing usually used with mica or graphite,
particularly in high temperature service.
Training Given by:> Aatif Alvi(03225131504)
Grafoil
A recent addition to the list of available packing materials is
Grafoil.
Grafoil is an all-graphite product that is flexible and has
direction-dependent properties.
It is essentially, chemically inert, except when strong oxidizers are
handled.
Training Given by:> Aatif Alvi(03225131504)
Inert Gas as a Packing
Another approach is to pressurize the area between the two packing
with inert gas at a pressure level, slightly higher than the fluid
pressure inside the valve.
In this case, the inert gas might leak into the valve, but no fluid is
allowed to leak by the stem.
This packing arrangement is more reliable.
Very Expensive
Training Given by:> Aatif Alvi(03225131504)
Cutting & making Rings
To make rings
Special Tool or With the help of a Electrician knife
How to cut and paste the rings
Cut Hare
Cut Hare
Training Given by:> Aatif Alvi(03225131504)
Gasket
Training Given by:> Aatif Alvi(03225131504)
Gaskets
Seat Ring Gasket
Upper Cage
Body Gasket
Material
Graphite / Grafoil
Asbestos
Neoprene
Training Given by:> Aatif Alvi(03225131504)
Leakage
Between:
Seat & Plug
Cage & Plug
Packing Material (Glands)
Bonnet
Flanges
Training Given by:> Aatif Alvi(03225131504)
To Check Valve is Passing
1.
Down stream isolating valve
2.
Body Temperature
3.
Valve Opening Reduces 50% 35%
4.
Abnormal Sound
Training Given by:> Aatif Alvi(03225131504)
Valve Leakage
Valve Leakage can be between
Seat and Plug
Cage and Plug
Packing Material
Bonnet
Flanges
Training Given by:> Aatif Alvi(03225131504)
Checks of Valve Passing
Downstream Isolating Valve
Body Temperature
Valve Opening Changes
Abnormal Sound
Training Given by:> Aatif Alvi(03225131504)
Detail of Reverse Acting Actuator Stem Seals
Training Given by:> Aatif Alvi(03225131504)
Gaskets
Flat Sheet Gaskets- Flat sheet gaskets are used as sonnet
gaskets and as seat ring gaskets.
Spiral-Round Gaskets -The role of a spiral wound gasket is
to flex, while maintaining a pressure tight seal, in order to
compensate for slight expansion and contraction of the
overall cage and seat ring height that results from thermal
expansion and contraction Because the spiral wound gasket
acts as a spring, it transmits the force that is required to
maintain a tight pressure seal over moderate temperature
changes.
Training Given by:> Aatif Alvi(03225131504)
Gasket Locations
Primary Gasket Locations
Training Given by:> Aatif Alvi(03225131504)
Construction and Visual Features of Gasket
Types
High-Temperature Spiral Wound Gasket (Standard)
Graphite Filler
(Flush With
Form)
Inconel Form
Flat Sheet Gasket
GraphiteLow Temperature Spiral Wound Gasket (Obsolete)
316 Stainless Steel Form
Composition Filler
(Protrudes Slightly)
Wire Screen
Green Stripe Indicates Composition (Low Temperature) Gask
Construction and Visual Features of Gasket Types
Training Given by:> Aatif
Alvi(03225131504)
Packing Options
Packing Options
The purpose of packing is to create a tight seal between the packing
bore and the valve stem to prevent fluid leakage to atmosphere.
Selection criteria for packing; includes:
Low friction so that the actuator can stroke the valve.
Compatibility of packing components with the process fluid.
Compatibility of packing parts with the set vice temperature.
Spring-Loaded PTFE Packing Arrangements
Spring-loaded PTFE packing arrangements are very common. A spring
loaded PTFE arrangement is shown on the following page.
Components - The packing box ring sits at the bottom of the
packing bore and provides a replaceable seat for the spring. The
spring transmits force to the packing rings through a washer. Male
and female adapters forth flat surfaces on the top and bottom ends of
the packing ring stack so that the packing mates squarely with other
components. The packing follower compresses (loads) the spring and
packing rings as the packing eland nuts are tightened.
Packing Rings - Because the packing rings are "V" shaped, the
spring load forces the edges of the rims-against the stem and the
packing boa bore to form a seal.
Training Given by:> Aatif Alvi(03225131504)
Packing Options
Pressure Assist - The concave surfaces of the packing rings always
face high pressure; therefore, process pressure also pushes the edges
of the rings against the valve stein and the packing box bore. The
orientation of the packing tings results - in a pressure-assisted seal.
Stem Requirements - Because nicks and burrs in the stem would
damage the packing rings as the valve is stroked, the valve stem must
be extremely smooth. Upper and lower wipers help to keep particles
from the process and the atmosphere from entering the packing bore.
Features- Spring-loaded PTFE packing arrangements. are popular
because;
They have low friction.
They are chemically compatible with a broad range of fluids.
They provide a tight seal.
They have -a long cycle life.
They provide constant loading (because of the spring) and therefore
require minimal maintenance
Training Given by:> Aatif Alvi(03225131504)
PTFE V-Ring Packing
Packing Flange Nut
Upper Wiper (Felt Washer)
Packing Flange
Packing Follower
Female Adapter
Packing Rings
Male Adapter
Spring
Packing Box
Ring
Lower Wiper
Single PTFE V-Ring Packing
Training Given by:> Aatif Alvi(03225131504)
Jam-style
packing are
arrangements
Jam-style PTFEPTFE
packing arrangements
also common. A jam-style
PTFE packing arrangement is' shown on the following page
Upper Wiper (Felt Washer)
Female Adapter
Packing Rings
Male Adapter
Lantern Ring
Jam-Style PTFE-Packing
Lower Wiper
Training Given by:> Aatif Alvi(03225131504)
Jam Style Graphite Packing
Arrangements
Jam Style Graphite Packing Arrangements
High-Temperature Applications - Graphite packing an
arrangements are commonly specified in applications where high
temperatures (temperatures above 450 degrees F) disallow the
use of PTFE materials, or in applications inhere it is necessary to
limit leakage through the packing bore in the event of a firs.
Graphite Packing Rings - A typical graphite packing arrangement
includes die formed ribbon rings and braided filament rings.
Graphite Packing Issues - Although graphite is well suited to
high temperature applications, graphite has several negative
characteristics, including the following:
Friction - Graphite is a high-friction material, and high friction can
cause jerky valve stem movement. If over tightened; graphite
packing may totally seize the valve stem.
Consolidation - Graphite tends to consolidate (compress) over time;
therefore, frequent packing adjustments are required. Sufficient
loading must be maintained in order to maintain a good seal.
Corrosive When Wet - Graphite tends to corrode. To prevent valve
and packing damage, sacrificial zinc washers are often included in
the packing arrangement.
Training Given by:> Aatif Alvi(03225131504)
Jam-Style Graphite Packing
Braided Filament Rings
Sacrificial Zinc Washers
Die Formed Ribbon Rings
Braided Filament Rings
Jam-Style Graphite Packing
Training Given by:> Aatif Alvi(03225131504)
High-Seal Graphite Packing, Live Loaded
High-Seal Graphite Packing, Live Loaded
Live-Loaded Packing With Load Scale - For extremely
high temperature and high pressure applications, a graphite
packing arrangement that does not include PTFE packing
washers may be specified. The graphite packing
arrangement that is illustrated opposite is rated to 1200
degrees F. However, the stern friction is extremely high and
packing loads must be carefully managed to prevent stem
seizure. An adjustable Belleville spring arrangement allows
precise adjustment of the packing loading.
As the Belleville springs are compressed (by tightening the
packing flange nuts), The load scale moves down relative to
the position of a fixed indicator disk. The position of the
indicator disk relative to the load scale provides a visual
indication of the amount of loading force that is applied to
the packing by the packing follower.
Adjustable Belleville Spring Operation - During
installation, the; Belleville springs are compressed until the
indicator disk aligns with the maximum (MAX) compression
line on the load scale. As the packing consolidates over
time, the
indicator disk moves toward the minimum (MIN)
Training Given by:> Aatif Alvi(03225131504)
compression line on the load scale., When the indicator disk
Hi -Seal Graphite Packing
Packing Flange Nuts
Belleville Spring
Load Scale
Maximum Compression Line
Minimum Compression Line
Indicator Disk
Packing Follower
Packing Ring (Composite)
Guide
Bushing
(Carbon)
Packing Ring (Die
Formed Graphite
Ribbon).
Packing Ring (Composite)
Guide Bushing
(Carbon)
Hi -Seal Graphite Packing, Live Loaded
Training Given by:> Aatif Alvi(03225131504)
Low-Leak Packing; Fisher Enviro-Seal
Low-Leak Packing; Fisher Enviro-Seal
Low Leakage Packing - In North America, the Environmental Protection
Agency (EPA) has set' forth strict guidelines for the maximum allowable
leakage of specific pollutants to the atmosphere. For many fluids and
applications, the maximum allowable leakage from gasketed joints and
stem packing is 500 ppm (parts per million). This low leakage
requirement has led to the development of several new packing
designs.
Enviro-Seal PTEE and graphite based, low leakage packingarrangements are- suitable for use in ANSI Class 125 through ANSI Class
600 valve bodies, Note the following general design features that
improve stem sealing.
Fewer Packing Rings - Low leakage packing arrangements include
fewer packing rings than standard pickings. The inclusion of fewer
packing rings results in a higher stress on each ring (more force in
terms of psi). The higher stress results in tighter sealing.
Reduced Stem/Packing Contact Area - This results in less stem and
packing wear, and unproved packing life.
Live-Loading - The packing is live-loaded through the use of externally
located Belleville springs. Live loading places a constant load on the
packing. Live-loaded packings require less maintenance than jam style
pickings.
Guiding-Massive guiding prevents lateral stem movement that can
result in packing damage,
Training Given by:> Aatif Alvi(03225131504)
PTFE
Enviro-Seal
Packing
PTFE
Enviro-Seal Packing
Preventing Extrusion- PTFE cold flows easily and it does
not have good memory; i.e. after PTFE becomes deformed, it
does not return to its original shape. When PTFE is used as a
packing ring material; a major concern is the extrusion of the
packing rings and the resulting loss of sealing integrity. Refer
to the figure below and note the anti-extrusion rings and antiextrusion washers that prevent packing ring extrusion.
Minimal Number of Rings - Because only a few packing
rings are included in the arrangement, there is extra space in
the packing bore Lantern rings are included to fill the empty
space.
Pressure/Temperature Ratings - The packing arrangement
that is shown opposite is designed' to meet the 500 ppm
leakage requirement at temperatures up to 450 degrees F
and at pressures up to 750 psig.
Training Given by:> Aatif Alvi(03225131504)
Enviro-Seal PTFE
Lubricate
O-Ring
Belleville Spring
Pack Assembly
Lantern Rings
AntiExtrusion
Washers
Anti-Extrusion Ring
Packing Ring
Anti-Extrusion Ring
Training GivenPTFE
by:> Aatif Alvi(03225131504)
Enviro-Seal
Graphite Enviro-Seal Packing
High Temperature Capability - When low stem leakage is required at
higher temperatures and pressures, graphite packing rings are included in the
packing arrangement.
Graphite and Composite Rings - The packing arrangement includes
graphite rings and composite rings. The major role of the composite rings is to
transmit the loading force to the graphite rings. The graphite rings perform
the primary sealing function.
Packing Washers - To create a tight seal, PTFE packing washers are included
between the packing rings. PTFE is typically limited to 400 to 450 degrees F to
prevent extrusion. In this application, however, extrusion of the PTFE actually
helps produce and maintain a tight seal. The racking arrangement that is
shown is designed to meet the 500 ppm leakage requirement at a maximum
temperature of 600 degrees F.
Guiding: Carbon Bushings - Graphite packing is not as resilient as PTFE
packing and any lateral movement of the stem will enlarge the packing' bore,
leading to leakage. To prevent packing damage and subsequent leakage,
carbon guide bushings are located above and below the packing rings to
provide stem guiding. The guide bushings are made of a non-metallic material
to prevent scratching; the stem.
Expanded Ratings- The ENVIRO-SEAL Graphite arrangement may also be
utilized in higher pressures up to 1500 psi and still maintain the 500 ppm EPA
leakage criteria.
Friction - Enviro Seal performance at elevated pressures and temperatures is
achieved at the expense of stem friction. Increased stern friction levels call
Training
Given by:> Aatif
require larger
actuators
andAlvi(03225131504)
mandate the use of positioners.
Graphite Enviro-Seal Packing
Enviro-Seal Graphite
O-Ring
Guide Bushing
Packing Ring (Composite)
Packing Washers
Guide Bushing
Packing Ring (Die
Formed Graphite
Ribbon).
Packing Ring (Composite)
Guide Bushing
Enviro-Seal Graphite
Training Given by:> Aatif Alvi(03225131504)
TRIM
Training Given by:> Aatif Alvi(03225131504)
Valve Trim
Those parts of valve which comes in direct contact of fluid.
Trim Comprises of:
Plug
Seat Ring
Stem
Cage
Training Given by:> Aatif Alvi(03225131504)
Trim
Material of trim depends on:
Process fluid & type, pressure, temp
Function of trim
Throttling
Flow characteristics
Shut-Off class
Training Given by:> Aatif Alvi(03225131504)
Flow
Characteristics
Flow
Characteristics
Definition Relationship between
the flow coefficient and valve travel
as the valve travels from 0 to 100
percent open.
Purpose of characterizing:
To provide uniform control loop
stability over the expected range of
operating conditions.
Training Given by:> Aatif Alvi(03225131504)
% of Rated Flow Coefficient
100
Valve Characteristic
0
Training Given by:> Aatif Alvi(03225131504)
% of Rated Travel
100
Plug - Linear
Training Given by:> Aatif Alvi(03225131504)
Plug - Equal Percentage
Training Given by:> Aatif Alvi(03225131504)
Plug - Quick Opening
Training Given by:> Aatif Alvi(03225131504)
Contoured Plug
Training Given by:> Aatif Alvi(03225131504)
Characteristics of Different Plugs
Valve Opening
30 %
70 %
100 %
90
100
Cv
Quick Opening
62
Linear
30
70
100
Equal %
33
100
V-Port
30
100
Training Given by:> Aatif
Alvi(03225131504)
Cage
A bit less hard material
But according to the requirement of process
Guides the Plug
Reduces the noise (10 to 15 db)
Flow characteristic
Slotted Cage
Training Given by:> Aatif Alvi(03225131504)
Sealing Gasket / Back up Ring
Training Given by:> Aatif Alvi(03225131504)
Cage Opening
Guided Valves Cage
Quick
Quick Opening cages provide maximum Cv at
minimal travel.
Visual Features
Square-edge window bottoms
% of Rated Cv
Applications
100
Relief
On-Off
Dump
Hi-gain
linear at low lifts
% of Rated Travel
100
Quick Opening Cage
Training Given by:> Aatif Alvi(03225131504)
Linear
Linear Cage
cages produce a percentage of maximum control
valve Cv that is directly proportional to valve stem position;
e.g., 60% travel = 60% maximum rated Cv.
Visual Features
Pear-shaped windows
Applications
Constant pressure drop applications
% of Rated Cv
100
Linear Cage
0
100
Training Given
by:>
Aatif Alvi(03225131504)
% of
Rated
Travel
Equal
Percentage Cage
Equal Percentage - Equal increments of change in stem
position produce an equal percentage change from the
existing Cv,
Visual Features
Alternately offset pear-shaped windows
% of Rated Cv
Applications
Many pressure and flow where
P decreases
as flow rate increases
100
Equal Percentage Cage
Training Given by:> Aatif Alvi(03225131504)
100
LINEAR
EQUAL PERCENTAGE
QUICK OPENING
Training Given by:> Aatif
Flow Characterized Cages for Globe-Style
Valve Bodies
Alvi(03225131504)
Flow Capacity
Training Given by:> Aatif Alvi(03225131504)
Cvs at Different Points of (Valve Travel)
Control Valve = Variable Restriction - The control valve
can be viewed as a variable restriction that is used to
modulate flow.
Valve Cv, versus Travel - In most instances, minimum
flow is achieved at no less than 10 percent travel, This
keeps the plug from throttling on the seat and help to
prevent instability problems. The maximum required flow
rate should
occur at
no is
more
than approximately
90
A Control
Valve
a Variable
Restriction
percent travel. That Provides Variable Cvs
Cvs at Different Points of (Valve Travel)
Training Given by:> Aatif Alvi(03225131504)
Influences
in Equation Form
Flow equation
Training Given by:> Aatif Alvi(03225131504)
Considering
Specific
Considering Specific
Gravity Gravity
Basic equation that utilizes the term C v is normalized for water at
60 degrees F The SG for water at 60 degrees F is 1.
Consideration for Fluid Specific Gravity
The base equation is normalized for water at 60 degrees F. To size
valves for other fluids, the term G is included
where:
Q =Flow Rate, gpm
CV =Valve Flow Coefficient
P= P2- P1
G= Fluid Specific Gravity
Training Given by:> Aatif Alvi(03225131504)
Fluid Pressure and Fluid Vapor Pressure
Fluid Pressure and Fluid Vapor Pressure
Vapor Pressure - pressure at which the fluid will change from a
liquid to a vapor (given a specific temperature).
Pvc< Pv - If the vena contracta pressure (P vc) falls below the vapor
pressure (Pv) of the fluid, then fluid vaporization will occur. This sets
the stage for choked flow.
Training Given by:> Aatif Alvi(03225131504)
Fluid Pressure and Fluid Vapor Pressure
Fluid Vaporization That Occurs When Pc< Pv
Training Given by:> Aatif Alvi(03225131504)
Post-Guided
Post-Guided Valves
Valves - For post-guided valves, flow
characteristics are determined by the contours of the valve
plug, as shown below
Characterized Valve Plug
Training Given by:> Aatif Alvi(03225131504)
Selection Guidelines
Process
Application
Guideline
Pressure
Liquid Process
Equal Percent
Gas, Small Volume
Equal Percent
Gas Large Volume Max dP < 5X Min dP
Linear
Gas, Large Volume Max dP > 5X Min dP
Equal Percent
Most
Equal Percent
Load Changes
Equal Percent
Set-point Changes
Linear
Max dP < 5X Min dP
Linear
Max dP > 5X Min dP
Equal Percent
Temperature
Flow
Liquid Level
Back Flow
Pressure
Constant dP Selection Guidelines
Characteristic
Linear
Training Given by:> Aatif
Alvi(03225131504)
Cavitations & Flashing
Training Given by:> Aatif Alvi(03225131504)
Flashing / Cavitations
Flashing
Flashing starts where cavitations end
Just like a sand blasting
Flashing liquid contains vapours
Vapours acts like a sand and liquid acts like a carrier
Cavitations
Two stage phenomenon
1st stage Formation of vapours
2nd stage Collapse or implosion of the cavitations back to the liquid
Cavitation in a globe valve.mp4
Result Cavitations Damage of trim material of valves.
Training Given by:> Aatif Alvi(03225131504)
Flashing
Training Given by:> Aatif Alvi(03225131504)
Cavitations
Training Given by:> Aatif Alvi(03225131504)
Positioner
Training Given by:> Aatif Alvi(03225131504)
Positioner Types
Positioner
Pneumatic
For Single
Acting
For Double
Acting
Electro-Hydraulic
ElectroPneumatic
For Single
acting
For Double
acting
Training Given by:> Aatif
Alvi(03225131504)
Digital Valve Controller
(Positioner)
LOOP CONNECTIONS TERMINAL BOX
1/2-INCH NPT CONDUIT
CONNECTIONS (BOTH SIDES)
OUTPUT A CONNECTION
SUPPLY CONNECTION
OUTPUT B CONNECTION
VALVE-MOUNTED
INSTRUMENT DVC6020
Digital Valve Controller
Training Given by:> Aatif Alvi(03225131504)
Type DVC6010 Digital Valve
Controller Mounted on Type 585C
Piston Actuator
Valve Controller Mounting
TYPE DVC6010 DIGITAL
VALVE CONTROLLER
MOUNTED ON A SLIDING
STEM CONTROL VALVE /
ACTUATOR
TYPE DVC6020 DIGITAL
VALVE CONTROLLER
MOUNTED ON A ROTARY
CONTROL VALVE /
ACTUATOR
Training Given by:> Aatif Alvi(03225131504)
TYPE DVC6005 BASE UNIT
AND DVC6025 FEEDBACK
UNIT MOUNTED ON A
ROTARY CONTROL VALVE /
ACTUATOR
3582 Series Pneumatic Positioner
Training Given by:> Aatif Alvi(03225131504)
Positioner
Training Given by:> Aatif Alvi(03225131504)
Control Valve Performance
Studies show that 80% control loops are not of optimal
performance and not proper sized control valves is the main
contributor
Some of the important design specifications for control valves
include:
Dead Band
Actuator- Positioner Design
Valve response time
Valve type and sizeing
Training Given by:> Aatif Alvi(03225131504)
Control Valve performance
Dead band in control valve is the prime objective in valve
tuning parameters
As most of the valves are used for regulating purpose, so even
1% dead band of the set point is not even acceptable
Actuator & positioner design should be closely monitored as it
plays important role in valve performance , usually actuator
and positioner are targeted to be of high gain so that the
losses of instrument air is minimum
Training Given by:> Aatif Alvi(03225131504)
Control Valve Performance
Valve Response Time : It is important that the valve react to
the set point quickly to make the control loop performance
improved
Valve sizing: is the important factor, we do not get the optimal
valve output if the valve is oversized or undersized
Training Given by:> Aatif Alvi(03225131504)
Valve Selection
General selection criteria
Pressure ratings: valves are available for pressure ratings for
classes 150,300,600, upto 2500
High temperatures require Valve packing selection
For high temperature PTFE-V rings are used
Training Given by:> Aatif Alvi(03225131504)
Material Selection
In most of the cases the piping material is best choice for
valve bodies
But this is not always the case as pressure drop at the valve
input is higher there fore the valve seat is of special
consideration
Carbon steel bodies and bonnets are the most widely used and
because of the low cost the most chose one
Alloy steel bodies&bonnets:When high temperature and high
pressure are involved
Training Given by:> Aatif Alvi(03225131504)
Material Selection
Stainless Steel : The most used the material selection is
stainless steel CF8M
Training Given by:> Aatif Alvi(03225131504)
