CONTROL VALVES

Part 1

Prepared by: Ramanathan

Reviewed by: Ezatolah Mardasi
Date: 15th October ‘03
CONTROL VALVES

Part 1 : an introduction
in appreciation

 Mr. Ezatolah Mardasi

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Contents
Basic
Terminology
Typesof Valves & Actuators
Accessories

Applications
General Service
Severe Service
Steam Service
Cryogenic Service

Anti-surge
Sizing & Selection
Characteristics
Datasheet
Sizingfor Valves & Actuators
Material Selection
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Codes & Standards
 TPCP Ruler
Technology Class: Base INSTRUMENT & PROCESS CONTROL “COMPETENCE MATRIX”

Ref. Competence levels: Awareness Knowledge Skill Level Advanced

Nr.
Technology:
5 Control Valves applications:

The knowledge and skill to select and specify the Ability to The ability The Skill -The skill to master all
appropriate body assembly of a control valve in order to -list the most common -to select the appropriate –to judge alternatives in aspects of valve
satisfy the actual process application. It includes the physical properties of a control valve body body construction, selection and on top of
selection of valve options to handle highly erosive control-valve assembly for all -to consider the required that to critical examine
applications, the selection of special materials and the -to list the basic process forthcoming process and achieved turndown process conditions,
specification of requirements for low-noise applications. parameters that are used conditions, ratio’s, provided by others with
Skills to understand the underlying principles of control in control-valve sizing. -to specify body -to judge maintenance respect to dynamic and
valve sizing as a part of a plant system with dynamic and materials with respect to aspects based on practical static pressure losses.
static gains/losses are needed. erosion/ corrosion, experience with aspects
Skills to master its application in actual practise for all -to perform a such as valve stand-time
process media are an integral part of the technology. computerised valve- (refers also to material-
sizing calculation and to selection),
select the most suitable -to consider dirt-handling
valve construction and maintenance
including the selection accessibility.
of an actuator. -to specify the
internationally defined
valve leakage factor,
acceptable for adequate
plant operation.

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 Control Valve - definition

A final controlling element, through which

a fluid passes, which adjusts the size of
flow passage as directed by a signal
from a controller to modify the rate of
flow of the fluid.

* ISA definition
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The major components

 Body
 Actuator

From Fisher Brochures 7

 Terminology - Valve Body
 Valve body - A housing for internal parts having inlet
and outlet flow connections

 Bonnet - The part of the body assembly which serves

as a means for mounting the actuator

 Cage - A hollow cylindrical trim element that is a guide

to align the movement of a valve plug with a seat ring.

 Seat - The portion of the valve body where the valve

plug contacts for closure.

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 Terminology - Valve Body
 Valve Plug - A movable part which provides a variable
restriction in a port.

 Valve Plug Stem - A rod extending through the bonnet

assembly to position the valve plug.

 Trim - The internal parts of the valve which are in contact

with the controlled fluid

 Port - A fixed opening inside the diameter of the seat ring

through which the fluid passes

 Packing Box - The part of the bonnet assembly used to

seal against leakage around the valve plug stem 9
Valve Body - Assembly

From Fisher Brochures 10

Actuators

An air operated mechanical device used to

open and close or modulate a valve. The
actuator is designed to convert air pressure
into mechanical force sufficient to operate
the valve.

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 Terminology - Actuators
 Diaphragm - A flexible pressure responsive element
which transmits the force to the actuator stem

 Actuator stem - The extension of the diaphragm plate or

piston for connection to the valve plug stem

 Actuator spring - The spring enclosed in the yoke is to

move the actuator stem in a direction opposite to that
created by the diaphragm pressure

 Piston - A movable pressure responsive element which

transmits force to the operating fluid

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Terminology - Actuators
 Yoke - The structure by which the diaphragm case is
supported rigidly on the bonnet.

 Travel Indicator - A pointer to indicate the travel of the

valve plug.

 Travel indicator scale - A graduated scale attached to

the yoke for indication of the travel.

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Actuators - Assembly

From Fisher Brochures 14

 Terminology - Control valve
 Valve Flow Coefficient (Cv) - The number of US gallons
per minute of 60°F water that will flow through a valve
with a one pound per square inch pressure drop

 Rated Cv - The value of Cv at the valve full-open position

 Rated Travel - The linear movement of the valve plug

from the closed position to the valve full - open position

 Leakage - The quantity of fluid passing through an

assembled valve when the valve is in the closed postion

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 Terminology - Control valve
 On-Off Service - When the valve is used to start / stop the flow
by being cycled to the full open or to full closed position

 Modulating Service - When the valve is being used to throttle

or regulate the flow by varying the opening between open and
closed positions

 Maximum shut-off Pressure - The pressure of the fluid flowing

into the valve against which the valve will have to close

 Service Temperature - The maximum and minimum

temperature of the media

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 Terminology - Control valve
 Supply Pressure - The plant air supply pressure available
to operate a pneumatic actuator

 Stem Torque - The force required at the valve stem to

open or close the valve against system pressure and
service conditions

 Capactiy - Rate of flow through the valve under stated

conditions

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 Terminology - Control valve
 Fail - close - The condition wherein the valve port remains
closed should the actuating power fail

 Fail - open - The condition wherein the valve port remains

open should the actuating power fail

 Fail - last - The condition wherein the valve port remains

in the last position should the actuating power fail

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 Control valve - end connections
 Threaded - for smaller size valves (< 2 “)
- isolation valves
 Flanged - common for all sizes
- most general & severe service
 Welded - for leak tight applications
- gas lines

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 Valve Plug Guiding
 Top and Bottom Guided
 Valve plug is aligned by guide bushings in the bonnet & bottom flange
 High stability and minimum deflection (high pressure drop applications)
 Cage Guided
 Valve plug is guided by a cylindrical cage throughout the travel range

 Increased trim life & lower stem friction (high pressure drop applications)
 Steam, gas and clean liquid applications only

 Stem Guided
 Valve plug is aligned with the seat ring by a guide bushing in the bonnet
 commonly used for throttling applications

 Top and Port Guided

 Valve plug is aligned by a guide bushing in the bonnet or body
and also the port
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Valve Plug Guiding

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Balanced trim

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Unbalanced trim

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Control Valve - Type of Body

 Angle
 Ball
 Butterfly
 Gate
 Globe

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 Control Valve - Angle Type
Controlling device - plug
Inlet to Outlet flow perpendicular

For slurry, viscous and flashing

applications in petrochemical
industries

Fisher, Valtek, Masoneillan

From Valtek Brochures25

 Control Valve - Ball Type
Controlling device - ball
High recovery
Tight shut-off

Gas transmission lines

Compressor stations
ESD valves

KTM, Groove, Oliver

From KTM Brochures 26

 Control Valve - Butterfly Type
Controlling device - vane
Low cost & light weight
Throttling & isolation
applications

Utilities (Water Supply)

Chemical Processing
Power Generation

Keystone, Tomoe, Cooper

From Keystone Brochures27
 Control Valve - Gate Type
Controlling device - Knife vane
Minimum resistance to flow
Easy maintenance
Quick and easy to operate

Utilites (water & waster-water)

Slurry applications
Multiproduct lines

Tomoe, Cooper, Velan

From Velan Brochures28
 Control Valve - Globe Type
Controlling device - plug
High accuracy control with
wide range of controllability

Petrochemical & chemical

applications
Refineries & Gas plants
Power plants

Fisher, Masoneillan, CCI

From Fisher Brochures

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Actuators

 Electric
 Hydraulic
 Pneumatic
 Spring - Diaphragm
 Piston - Spring return
 Piston - Springless
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 Electric actuators
The actuator operates the
valve using an electric
motor driving a gear train

Electrically
driven actuator
contain an internal spring to

close the valve on loss of

electricity

Motor operated valves

Rotor, Bettis, Limitorque

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From Rotork Brochures
 Spring - diaphragm actuators
Actuation through a
diaphragm by low pressure
Light weight

Wide range of control

applications (on/off and
modulating)

Bettis, Biffi, Limitorque

From Fisher Brochures32

Piston - spring return actuators
Pneumatic actuators with springs

oppose the movement of a piston

or diaphragm. When the air

supply is discontinued or
exhausted, the spring extends
and drives the piston / diaphragm
in the opposite direction.

Commonly used for fail to open

and fail to close applications From Biffi Brochures 33
 Piston - springless actuators
 Air or nitrogen is used to pressurize
a double acting cylinder. A solenoid

valve is used to switch pressure

between the cylinders

 Commonly used for fail last position

 Biffi, Limitorque, Bettis

From Bettis Brochures34

Accessories

 Air Filter Regulator

 Booster
 Handwheel
 Limit Switch
 Lock-up Relay
 I/P Positioner
 Solenoid Valve
 Travel Stop
 Volume Tank 35
 Accessories - Air Filter Regulator
 Air filter regulators are used to
filter and regulate the supply
pressure to actuators and
positioners (removal of dust
particles and water content)

From Dezurick Brochures 36

Accessories - Booster
The booster is used in
conjunction with a positioner
on a throttling control valve to
increase stroking speed

From Becker Brochures37

 Accessories - Handwheel
The handwheel is utilized
when pneumatic / electric
power is not available for the
actuators.
(It utilizes a system of gear
multipliers to develop necessary
torque to close/open the control
valve)

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From Becker - Brochures
Accessories - Limit Switch
 Limit Switches are devices to
indicate that the valve cycle has
been completed or to indicate
the actual valve position
 These signals are also used as
interlocks in a control system
(For example, locking out a
pump until its supply valve has
been opened)

From Weslock Brochures39

Accessories - Lock-up Relay
Air Lockup device holds the air in
locked condition when the supply
air pressure falls below the set
value; thereby keeping the control
valve in stay-put condition.

From Yamatake Brochures40

Accessories - I/P Positioner
Adevice attached to the
pneumatic actuator, providing
automatic modulating control of

between the open and closed

positions by balancing the air
supply to the actuator through
the input signal

The pneumatic positioner is

designed to receive a 3 to 15 PSI
signal, while the electro-
pneumatic is designed to receive
a 4 to 20 milliamp signal From Trac Brochures 41
 Accessories - Solenoid Valve
An electro-magnetically operated
valve which enables electrical
control of the air supply to a
pneumatic actuator

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From Magnetrol Brochures
 Accessories - Travel Stop
A mechanical device
to limit the travel in both
direction

To prevent accidental

actuation while the valve
is in the open or close
position

From Keystone Brochures43

Accessories - Volume Tank
The volume tank
provides the loading
pressure for the actuator
when supply pressure falls

From Burket Brochures44

 Summary
 Definiton of control valve

 Terminology for control valve and actuators

 Definition of actuator
 Types of valves
 Types of actuators
 Accessories

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Next
Applications
General Service
Severe Service
Steam Service
Cryogenic Service
Anti-surge
Sizing & Selection
Datasheet
Material Selection
Codes & Standards
Sizing for Valves
Sizing for Actuator 46
Thank you

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