CONTROL

VALVES
Rejath Jacob Thomas
 CONTROL VALVE - An Introduction

Ø A Control Valve is the most commonly used

final control element used to regulate fluid flow in
a process. In a process, normally it is the only
controllable element residing in the loop.

Ø This is a device used to modulate flow of

process fluid in pipe lines by creating a variable
area in the flow path.

Ø The flow path is varied with respect to the

control signal received from the controller
towards the required flow modulation.

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CONTROL VALVE - ISA Definition

International Society of Automation -

ISA (previously known as Instrument
Society of America) defines the control
valve as a power operated device that
modulates the fluid flow rate in a
process control system

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CONTROL VALVE - In a process control loop

Representation of a typical process control loop

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CONTROL VALVE - PARTS

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 PARTS OF CONTROL VALVE
ØValve body assembly

• Body
• Bonnet Pressure Retaining Components
• Bolting
• Seat ring
• Plug
• Stem
• Cage Trim Materials
• Packing
• Seal ring
• Gasket and shim
ØActuator assembly

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 VALVE BODY
Main fluid boundary and pressure containing component

It Includes

• Provision for securing internal parts

• End connections that allows installation in the pipeline
• Provision for attaching the bonnet

BODY

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 BONNET
• Also a major pressure containing component and
fluid boundary
• Bolted or threaded into valve body
• Bonnet locates and guides the valve stem and it
includes a bore for packing (packing box)
• Also includes yoke boss or some other means
mounting an actuator

BONNET

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 TRIM
• Trim refers to all internal parts of a valve which
are in flowing contact with the controlled fluid
[also referred to as “Wetted” parts]
• It includes the valve plug, stem, cage, seat ring,
plug sealing rings, gaskets and packing parts

Trim Parts

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 TRIM COMPONENTS

Ø Plug
Provides throttling control and shutoff in globe valves

Ø Seatring
Seat rings in globe valves work with the valve plug to
arrest leakage.

ØCage
Provides plug guidance and flow characterization

ØStem
Connects the plug to the actuator

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 PARTS OF CONTROL VALVE - Contd

Ø Stem Connector
A Clamp in two pieces to connect the actuator stem to
the valve plug stem.
STEM
CONNECTOR

YOKE

ØYoke
The connecting structure / part between the Valve
Actuator and the bonnet assembly.

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 PARTS OF CONTROL VALVE - Contd
Ø Gaskets
Provides sealing between mating surfaces.
• Bonnet gasket :
Between Body and bonnet
• Seat ring gasket :
Between seat ring and body

Ø Packing
Prevents leakage of the fluid through the valve stem
• Packing is compressed to form a tight seal
between the packing box wall and the valve
plug stem

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 ACTUATOR

It the part of the valve which generates the motive

power. It is the mechanism which operates the valve
plug, in correspondence to the control signal received
from the controller.

ØActuators Types:

• Pneumatic
Spring Diaphragm
Piston Cylinder
• Electrical
• Hydraulic

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 VALVE ACCESSORIES

ØPOSITIONER
•Pneumatic
•Electro-pneumatic
•Conventional
•SMART – HART
•Foundation Field bus

ØPOSITION SWITCHES
•Inductive
•Mechanical Cam Operated

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 VALVE ACCESSORIES – Cont . . .
ØSOLENOID VALVE
•Latching type
•Manual Reset

ØVOLUME BOOSTERS

ØAIR LOCK RELAY

ØAIR FILTER REFULATOR

ØAIR VOLUME TANK

ØHANDWHEEL
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 VALVE TERMINOLOGIES
ØCapacity : It is the ability of the valve to allow fluid flow through
it under stated condition.

ØCv –Valve Coefficient : It is the unit of measurement to define

the capacity of a valve. The number of US Gallons of water at 60
degrees F that will pass through a valve with a drop of one pound
per square inch in one minute.

ØVALVE Kv : Quantity of water in M3/Hr. at temperature

between 5 to 40 degrees C that will flow through the valve at a
specified travel with a pressure drop of 1 Bar.
•Kv = 0.856Cv

ØRated CV : Value of Cv at full open position.

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 TERMINOLOGIES Cont . .
ØRangeability:
Rangeability of a Control Valve is defined as the ratio of the
maximum controllable flow to the minimum controllable flow. The
Inherent rangeability of a valve is the ratio of the maximum and
minimum flow under constant pressure differential . Hence it is
expressed as Cv Max divided by Cv min.

ØLeakage:

Quantity of fluid passing through an assembled valve when the

valve is in the closed position under stated closure forces with
pressure differential and pressure specified. [ref to ANSI B-16 –
104-1976]

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 TERMINOLOGIES Cont . .
ØValve Characteristics:
It is a relation between flow through the valve & percentage
rated travel as the latter is varied from 0-100%.

•Inherent characteristics:
Flow characteristics when constant pressure drop is maintained
across the valve.

•Installed Characteristics:
Flow characteristics when pressure drop across the valve varies
as dictated by flow and related conditions in the system in which
the valve is installed.

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 CONTROL VALVE - CLASSIFICATION
ØDepending on the motion of the plug

Linear Rotary
Each type of valve has its special generic features, which
may, in a given situation, be either an advantage or a
disadvantage

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LINEAR VALVES ROTARY VALVES

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 CONTROL VALVE - CLASSIFICATION
ØDepending on the motion of the plug
Linear Motion Globe Globe Single Seated
Double Seated
Diaphragm Angle Split body
Pinch or Clamp 3-Way

Control Valve

Rotary Motion Butterfly Swing Through

Eccentric Plug Lined
Eccentric
Ball Segmented
Full
V-Notch

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 SINGLE SEATED GLOBE VALVE

Sizes : 1/2" to 16" Higher sizes available on

request

Application :
To control large range of process parameters,
specially for oil and gas production, power
generation, chemical, petrochemical,
fertilizer, pharmaceutical, processed food
and other process industries.

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 SINGLE SEATED GLOBE VALVE
Features :
Ø High flow capacity and high gain
Ø High powered actuator, field reversible
Ø Streamlined flow passage and excellent flow control
rangeability
Ø Tight shut off permissible
Ø High rangeability using low flow trims
Ø Large variety of trim design varying from contoured trims to
single stage ported and multiple stage low noise anti
cavitation trims
Ø Can be supplied with wide range of interchangeable trim
sizes
Ø Characteristics - Equal percentage, Linear and Quick open
Ø Leak proof packing are available on request

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 DOUBLE SEATED GLOBE VALVE

Sizes : 11/2" to 18" (40 - 450 mm) Higher sizes

available on request

Application :
For high flow and high pressure services

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 DOUBLE SEATED GLOBE VALVE

Features :

Ø High Flow Capacity Minimum differential plug areas to

reduce actuator force requirement

Ø Optional anti - cavitation / low noise trim option for high

pressure drop application

Ø Characteristics - Equal percentage, Linear, Quick open

Ø Leak proof packing are available on request

Ø Heavy duty top and bottom guided construction

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 ANGLE VALVE

Sizes : 1/2" to 6"

Application :
Specially for very high pressure drop and also used where the
fluids contain solid particles.

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 DOUBLE SEATED GLOBE VALVE
Features :
u High Flow Capacity

u Tight shut off

u High rangeability

u Body proportioned to withstand high pipe stresses without

distortion

u Wide range of interchangeable trim styles and sizes

available

u Adaptability to specialist duties i.e. venturi outlet, low noise

etc.

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 THREE WAY VALVE

Definition : is ideal for blending two separate flows, by having

two inlets and a common outlet, or dividing a flow into two
proportional parts by having one common inlet and two outlets.

Sizes : 1/2" to 12“ Higher sizes available on request

Application :
For high temperature fluid and particularly for textile industries, to mix or divert fluids

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 THREE WAY VALVE
Features :

u High Flow Capacity

uLeakage capability better than ANSI class IV & consistent

with normal single seat valve

u High rangeability

u Leak proof packing are available on request

u Valve is used for mixing or diverting services depending on

customers requirement

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 THREE WAY VALVE

MIXING SERVICE DIVERTING SERVICE

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 BELLOWS SEALED VALVE
Definition : Available as additional feature to give a leak
proof packing in the single seated, double seated and three
way valves.

Application :

For hazardous and corrosive fluids.

Features :
u Bellows are of stainless steel to withstand high
pressure & temperature.

uPTFE bellows available for low pressures on

request.

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 BUTTERFLY VALVE

Sizes : 2" to 36"

Application :

Steel, Sugar and textile industries and specially for fluid

containing slurry particle. Used for on-off as well as
control applications.

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 BUTTERFLY VALVE
Features :

u Water style connection Concentric design as

standard, offset design for special application

u Metal to metal or Sleeved type construction

u Choice of various rubber or PTFE sleeves

u Tight shut off with rubber sleeves

u Minimum obstruction for flowing media

u High Flow Capacity

u Simple & Light construction

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 BALL VALVE

Sizes : 1/2" to 8" (15 - 200 mm)

Application :
Used in paper, Pulp and textile industries

Features :

uTight shut off Minimum obstruction for the flowing

media

u High Flow Capacity

u 'O' Ball & 'V' Notch construction available

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 DIAPHRAGM VALVE

Sizes : 1/2" to 14"

Application :

For water treatment plant, caustic soda plant, chemical

plants, fertilizers, specially for corrosive fluid.

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 DIAPHRAGM VALVE
Features :
u Castings standardized to IS 210 FG grade cast Iron

u Better sealing and longer diaphragm life with the help of weir
design

u Stronger bonnet design to take care of higher thrust and

support to the diaphragm

u Diaphragm construction design with exclusively reinforced

fabric

u Fail safe assembly on auto valves totally protects process

operation in the event of electrical power or air supply failure

u Available in various linings to handle different fluids

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VALVE CLASSIFICATION - ACTUATOR TYPE

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VALVE CLASSIFICATION – END CONNECTION

Ø SCREWED
Ø WELDED END
• BUTT WELDED
• SOCKET WELDED
Ø FLANGED END
• RAISED FACE, RF
• FLAT FACE, FF
• RING TYPE JOINT, RTJ

Ø WAFER TYPE
Ø WELDED END
Ø WELDED END
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End connection – Screwed end

• Popular for small control valves because of their economy and

ease of installation
• Not available for bodies above 2 inch in size
• Aligning the threaded in valve with pipelines needs extreme care
and mismatch may lead to damage to thread in valve

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End connection – Welded end
• For high pressure and high temperature applications
• Valve body is directly welded into the pipeline
• Leak tight at all pressure and temperature
• Economical
• Socket weld ends are common for smaller valve sizes and butt
weld ends are standard for sizes 2-1/2 inch and larger valve bodies
• Precise alignment of valve body with pipe line is mandatory for
welded end connection

Butt Weld Socket Weld

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Butt welded end

Butt Weld end

Connection

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End connection – Raised Face (RF)

• Most common end connection

• Flange has circular, raised faces with concentric circular grooves
for good gasket sealing and resistance to gasket blowout
• Gasket only covers the raised face portion of the flange
• As line bolting is tightened, high stresses are produced at the
perimeter of each flange
• Not available for brittle/Soft material like Cast Iron, Bronze etc.

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End connection – Flat Face (FF)

• Allows full face contact with gasket clamped between the flanges
• Full face contact has the advantage of minimizing flange stresses
caused by forces of line bolting
• This type of flanges are common in cast iron bodies which are
brittle and would crack if raised face flanges were used. Flat face
flanges are also common in brass and aluminum bodies
• These materials are soft and would bend if raised face flanges
were used

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End connection – Ring type joint (RTJ)
• Well suited for extremely high pressure applications but generally
not used at high temperature
• Mating grooves in the body and pipe flanges retain a solid metal
seal ring
• As the line bolting is tightened the ring deforms and conforms to
the grooves
• Pressure assisted seal; since as the pressure increases, the ring
pushes against the grooves
• Soft iron or Monel is generally used as gasket material

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End connection – Separable flange
• Flanges are manufactured independently of the valve body
• Split rings are required to secure the flange to the body and to
transmit the bolting force to the gasket and mating connection
• If the body material is expensive separable flanges may result in
economy since flanges can be made of an economical material
like carbon steel

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End connection – Wafer style

• Generally called as Wafer style or flangeless

• Includes a raised-face contact surface in the body casting
• Long line bolting sandwiches the body and gasket between the
pipe flanges
• This is more economical body style since it requires less material
for construction
• Ball and butterfly valves are commonly available with this body
style

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Shutoff class

ØImportance of control valve shutoff

• To maintain proper operation of a process

– If a control valve leaks excessively in closed position the
leakage may affect the downstream processes & end
product quality

• To avoid potential damage to the valve in certain applications

– If a valve in boiler feed water application leaks, the high
velocity streams that leaks across the seat can erode
critical seating surfaces

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Shutoff class

ØThe ability of a control valve to prevent flow from the inlet side
to the outlet side of the valve in the fully closed condition.

ØANSI/FCI 70-2 came up with different shutoff classes to

standardize leakage across control valve

ØTo provide a range of shutoff options linear valves have

different type of plug and seat construction

ØRotary valves have various seal configuration and materials to

offer a range of shutoff

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Shutoff class
ANSI/FCI Leakage Classes
ANSI/FCI 70-2 Maximum Leakage Test Medium Pressure and temperature
Class II 0.5% valve capacity at full travel Service DP or 50 PSID
Class III 0.1% valve capacity at full travel Water / Air whichever is lower at 10 to
Class IV 0.01% valve capacity at full travel 52deg C
Class V 0.0005ml/min/psid/in. port dia Water Service DP at 10 to 52deg C
Bubbles per
Port dia. mL per Min.
Min.
1 1 0.15
1 - 1/2 2 0.30 Service DP or 50 PSID
Class VI 2 3 0.45 Air whichever is lower at 10 to
2 - 1/2 4 0.60 52deg C
3 6 0.90
4 11 1.70
6 27 4.00
8 45 6.75

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Flow Characteristic

Ø Relationship between flow through the valve and the

plug/disc travel.

Flow Characteristics

• Quick opening-Shut off & Fast flow

• Linear-Liquid level control

• Equal percentage-Pressure & Flow control

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Why Characterization?
ØTo compensate the process gain changes so that loop gain
remains independent of load.
ØTo provide uniform control loop stability over the expected range
of operations.
ØTo match the valve gain to the system gain for optimum
performance.

Characteristics methods:
• Trim shaping
• Positioner characterization
• Controller characterization

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Valve Characteristics

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Quick opening

• Inherent flow characteristic with high flow at initial % of travel.

• High and constant gain at initial half of its travel.

• Decreasing gain at travel above 70%

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Equal percentage

• Equal increments of change in valve travel produce equal

percentage changes in the existing flow coefficient

• Provides low valve gain at low percentage of valve travel, and

high valve gain at higher percentage of valve travel

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Linear Characteristics

• Flow is a linear function of travel

• Gain remains constant throughout the travel i.e 1

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Cage Shapes

Quick opening Linear Equal percentage

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Plug Shapes

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Plug Shapes

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Plug Shapes

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Inherent Characteristics

• Relationship between flow rate and valve travel, under

constant pressure drop conditions

• Inherent valve characteristics can be Quick opening,

Linear, Equal percentage

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Inherent Characteristics

u Flow at constant pressure drop

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Installed Characteristics

• Relationship between flow rate and valve travel, under actual

process conditions

• Installed flow characteristics is process dependent where

pressure drop changes with process variable

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Installed flow Characteristics

u Flow at varying pressure drops

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Valve Gain

Ratio of change in flow to change in stem travel

Valve Gain =

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Guidelines for selection of Valve
Characteristic

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Non Linear Process

• At Low flow, change in input signal will cause large change in

flow-rate.

• At high flows, the change in input signal will cause very small
change in flow-rate

• Impossible to tune controller for stability as the controllability

and the operating range sometimes is out of boundaries

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Compensation- for Non linear process

• To provide linear gain over entire system, in a non linear

process, equal percentage characteristic is chosen.

• The Equal Percent’s low gain compensates for high gain at

low flow

• Similarly, the Equal Percent’s high gain Compensates for

low gain at high flow

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Application guidelines

PROCESS APPLICATION GUIDELINES

Pressure Liquid process Equal Percent
Gas, Small volume Equal Percent
Gas , Large volume Linear
Max dP < 5X Min dP

Gas , Large volume Equal Percent

Max dP > 5X Min dP

Temperature Most Equal Percent

Flow Load changes Equal Percent
Set point changes Linear
Liquid Level Max dP<5X Min dP Linear
Max dP>5X Min dP Equal Percent
Back Pressure Constant dP Linear

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Body/Bonnet material – carbon steel body

Ø Most commonly used carbon steel bodies are WCC and LCC

Ø WCC – Weldable Carbon steel Cast

• Can be used between -29 to 427 deg

• Above 427 deg C graphitization can occur

• Preferable to killed carbon steel

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Body/Bonnet material – carbon steel body

ØLCC – Low temperature carbon steel cast

• Same chemical composition as WCC

• Quenched and tempered in order to meet impact requirement

• Can be used between -46 to 343 deg C

• Impact tested for confirming suitability

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Body/Bonnet material – Alloy steels

ØAddition of Chromium and molybdenum enhances the resistance

to graphitization and tempering at elevated temperature

• WC6 : -29 to 593 deg C

• WC9 : -29 to 593 deg C

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Body/Bonnet material – Stainless steel

ØFor increased high temperature capability and for increased

pressure retaining capability, Alloys with still more chromium and
molybdenum are specified

ØTo avoid sensitization (formation of carbides) carbon content is

kept low in stainless steel

ØCF8M, CF3M, CG8M, CF8C

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P&ID symbols of various control valves per ISA S5.1

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 Applicable codes and standards
Ø ASME B16.34 - valves - flanged, threaded and welding ends

Ø ASME B1.20.1 - Pipe threads

Ø ANSI FCI 70-2 - Control valve seat leakage

Ø ISA 71.01 - Environmental conditions for process measurement & control

systems: Temperature and Humidity

Ø ISA 75.01 - Flow equation for sizing control valves

Ø ISA 75.03 - Face to face dimensions for flanges globe-style control valve bodies

Ø ISA 75.04 - Face to face dimensions for flangeless control valves

Ø ISA 75.17 - Control valves aerodynamic noise prediction

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 Applicable codes and standards
Ø NEMA ICS 6 - Enclosures for Industrial controls and systems

Ø IEC 529 - Specification for degree of protection provided by enclosure

Ø NFPA 70 - National electric code

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 Major vendors

Valve Assembly Actuators

= EIM

Ø Masoneilan Dresser = Bettis

Ø Fisher = Keystone

Ø Flowserve (Valtek) = Automax

Ø Tyco = Rotork

Ø Instrumentation Limited = Limitork

Ø Metso

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Thank You !

Questions?

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