CONTROL VALVES

Course Outline
Introduction to Control Valves
Valve Body
Valve Actuators Types
Valve Accessories
Control Valve Sizing & Valve
Characteristics
Control Valve Problems
Actuator Sizing
Installation and Maintenance
Control Valve

A Control Valve is the most

commonly final control element
used to regulate material flow in
the process.
Body
Sliding-stem valves
Globe valves
Globe valves restrict the flow of fluid by altering the distance
between a movable plug and a stationary seat. Fluid flows
through a hole in the center of the seat, and is more or less
restricted by how close the plug is to that hole.
Single Seated
Globe valves
Double Seated Globe Valve
Cage
Cage-guided globe valves
Way Globe Valve-3
Angle Globe Valve
 Gate valves

Gate Valve Movie

Diaphragm valves
video
Rotary-stem valves
Ball valves
Segmented Ball
(Characterized);
Ball Valve Movie
Butterfly valves
Butterfly valves
Disk valves
Dampers and louvers
Valve packing
Valve Packing Video
 Extension Bonnet: A Bellows Seal Bonnet “a
bonnet with greater physical barrier or seal “:
dimension between the A bonnet that uses a
packing box and bonnet bellows for sealing
flange for hot or cold against leakage around
Valve seat leakage
Control valve actuators
1. Pneumatic actuators
Diaphragm actuator for rotary
valves
Pinion and Rack
Hydraulic actuators .2
Self-operated valves 3
4. Electric actuators
hand crank for manual
operation, in the event that the
electric motor fail
Actuators
Valve failure modes
Direct/reverse actions
Actuator bench-set
F = kx
Sliding Steam assembly
Pneumatic actuator
response
Booster Relay
Booster Relay are used to reduce
lag time, resulting from long
transmission lines or when
controller output capacity is
insufficient for high demand
device.
Lockup Valve
Used when it is required to
remain the valve at it’s last
position in the event of air supply
pressure failure.
Valve positioners
Force-balance pneumatic positioners
Motion-balance pneumatic
positioners

Fisher model 3582 pneumatic motion-balance

Electronic positioners
(Smart positioners)

Siemens PS2 Valve Positioner movie

Limit Switches
Proximity Switches
Limit switch Box
Valves Solenoid
2-way solenoid valves
way solenoid valves-3
Directional Control
Valves
Two-Way Directional
Valve
Four-Way Directional
Valve
Five-Port / Four-Way
Directional Valve
Schematic Symbols for
Directional Valves
Electro-Pneumatic
transducer (I/P)
Foxboro model E69 (I/P)
Split-range
Control Valve
Sizing

The act of choosing an appropriate control valve for

the expected energy dissipation is called valve sizing.
The flow coefficient of a control valve (Cv) is a numerical value
expressing the number of gallons per minute flow of water the
valve will pass with a constant pressure drop of 1 PSI from inlet
to outlet.
Steps to Size Valves for Liquids
5.
1. Specify the variables required to size the valve as follows:
•Process fluid (water, oil, etc.),
and
•Appropriate service conditions q or w, P1, P2 or ΔP, T1, Gf,
Pv, Pc, and 

.Determine the equation constant, N .2

3. Determine Fp, the piping geometry factor.

4. Determine qmax (the maximum flow rate at given upstream

conditions) or ΔPmax (the allowable sizing pressure drop).

6. Select the valve size using the appropriate flow coefficient

table and the calculated Cv value.
Determining Fp, the Piping Geometry Factor
 Determining qmax (the Maximum Flow Rate) or ΔPmax (the
Allowable Sizing Pressure Drop)

For valves installed without fittings

For valves installed with fittings attached

Exampl
e
Gas valve sizing
Steps to Size Valves for
Compressible Fluids
5. For volumetric flow rate units—
•If the specific gravity, Gg, of the gas has been specified:

•If the molecular weight, M, of the gas has been specified:

For mass flow rate units—

•If the specific weight, ɤ1, of the gas has been specified:

•If the molecular weight, M, of the gas has been specified:

1. Specify the necessary variables required to size the valve
as follows:
•Process fluid (air, natural gas, steam, etc.) and
•Appropriate service conditions— q, or w, P1, P2 or _P, T1, Gg,
M, k, Z, and ɤ1

2. Determine the equation constant, N.

3. Determine Fp, the piping geometry factor.

4. Determine Y, the expansion factor, as follows:

6. Select the valve size using the appropriate flow coefficient
table and the calculated Cv value.

Determining xTP, the Pressure Drop Ratio Factor

Example1
Exampl
e2
 Control Valve Characteristics
Inherent versus installed characteristics
Control valve performance with
constant pressure
Control valve performance with
varying pressure
Characterized valve trim
Shapes of Globe Valve
Trim
Cage Guided
Globe

Ball Valve
Trim
Conclusion:

1. Equal Percentage: equal increments of valve travel

produce an equal percentage in flow change
2. Linear: valve travel is directly proportional
to the valve stoke
3. Quick opening: large increase in flow with
a small change in valve stroke
Here are some rules of thumb for each one:

1. Equal Percentage (most commonly used valve control)

a. Used in processes where large changes in pressure drop are
expected
b. Used in processes where a small percentage of the total
pressure drop is permitted by the valve
c. Used in temperature and pressure control loops

2. Linear
a. Used in liquid level or flow loops
b. Used in systems where the pressure drop across the valve is
expected to remain fairly constant (ie. steady state systems)

3. Quick Opening
a. Used for frequent on-off service
b. Used for processes where "instantly" large flow is needed
(ie. safety systems or cooling water systems)
Gate Valves
Best Suited Control: Quick Opening
Recommended Uses:
1. Fully open/closed, non-throttling
2. Infrequent operation
3. Minimal fluid trapping in line
Applications: Oil, gas, air, slurries, heavy liquids, steam, non
condensing gases, and corrosive liquids

Globe Valves
Best Suited Control: Linear and Equal percentage
Recommended Uses:
1. Throttling service/flow regulation
2. Frequent operation
Applications: Liquids, vapors, gases, corrosive substances,
slurries
Ball Valves
Best Suited Control: Quick opening, linear
Recommended Uses:
1. Fully open/closed, limited-throttling
2. Higher temperature fluids
Applications: Most liquids, high temperatures, slurries

Butterfly Valves
Best Suited Control: Linear, Equal percentage
Recommended Uses:
1. Fully open/closed or throttling services
2. Frequent operation
3. Minimal fluid trapping in line
Applications: Liquids, gases, slurries, liquids with
suspended solids
Packing Selection Guidelines for Sliding-Stem Valves
Packing Selection Guidelines for Rotary Valves
Control Valve Problems
1. Mechanical friction
2. Flashing
3. Cavitation
Cavitation video
Choked flow .4
5. Valve
noise
6. Erosion
7. Chemical attack
 Actuator Sizing
Actuators are selected by matching the force
required to stroke the valve with an actuator
that can supply that force. For rotary valves a
similar process matches the torque required to
stroke the valve with an actuator that will
supply that torque. The same fundamental
process is used for pneumatic, electric, and
electro hydraulic actuators.
Sliding Stem Valves Actuator Sizing
A. Unbalance Force
Unbalance force = net pressure differential X
net unbalance area
 B. Force to Provide Seat Load

Minimum Required Seat Load for Metal-Seated Valves for Improved Seat Life for Class II-V
and Recommended Seat Load for Optimum Performance in Boiler Feedwater Service
C. Packing Friction
D. Additional Forces
Additional forces may be required to stroke the valve
such as: bellow stiffness; unusual frictional forces
resulting from seals; or special seating forces for soft
metal seals as an example.
Actuator Force Calculations
The force required to operate a sliding stem valve
includes:
A. Force to overcome static unbalance of the valve
plug
B. Force to provide a seat load
C. Force to overcome packing friction
D. Additional forces required for certain specific
applications or constructions
Total force required = A + B + C + D
Rotary Valve Actuator Sizing

Breakout Torque

TB = A(ΔPshutoff) + B

Dynamic Torque

TD = C(ΔPeff)
Typical Rotary Shaft Valve Torque Factors V−Notch Ball Valve
with Composition Seal

High Performance Butterfly Valve with Composition

Seal
Installation and Maintenanc
1. Proper Storage and Protection
2. Proper Installation Techniques
Read the Instruction Manual 2.1
Be Sure the Pipeline Is Clean 2.2
2.3 Inspect the Control Valve
2.4 Use Good Piping Practices

Tighten Bolts in a Criss-cross Pattern

Control Valve Maintenance approache
Reactive – Action is taken after an event has occurred.
Wait for something to happen to a valve and then
repair or replace it.

Preventive – Action is taken on a timetable based on

history; that is, try to prevent something bad from
happening.

Predictive – Action is taken based on field input using

state-of-the-art, non-intrusive diagnostic test and
evaluation devices or using smart instrumentation.
 Instrument Air Leakage
Supply Pressure
Travel Deviation and Relay Adjustment
Instrument Air Quality
In-Service Friction and Friction Trending
Actuator Diaphragm
Stem Packing

Seat Rings
Grinding Metal Seats
Replacing Seat Rings
Bench Set