Control Valve

Anil Kumar Bag

Asst. Professor, Department of AEIE
Heritage Institute of Technology, Kolkata (HIT-K), Anandapur, Kolkata-700107
[email protected]
Control Valve

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 Control Valve
Final Control Elements (FCE):

 The common energy source of final control elements are:

• Electric
• Hydraulic
• Pneumatic

 Electric :
• Electric Heater, Thyristor Bridge
• Solenoid
• Stepping Motor
• DC Motor
• AC Motor 3
 Control Valve

The control valve manipulates a flowing fluid, such

as gas, steam, water, or chemical compounds, to
compensate the disturbance occurs in the process
and keep the process variable as close as possible
to the desired set point.

A “control valve” regulates the flow of fluid through

a pipe in response to the signal from a loop
controller or logic device.
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 Control Valve- Constructional Parts

Control valves are comprised of two major parts:

The Valve Actuator, which provides the mechanical

power necessary to move the components within
the valve body.

The Valve Body, which contains all the mechanical

components necessary to influence fluid flow.
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 Major Components of Control Valve

Direct Acting Actuator: A diaphragm actuator in which the actuator stem moves down
with increasing diaphragm pressure. 6
 Major Components of Control Valve

Reverse Acting Actuator: A diaphragm actuator in which the actuator stem moves up with
increasing diaphragm pressure. 7
Major Components of Control Valve

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 Control Valve
The control valve assembly typically consists of
• the valve body,
• the internal trim parts,
• an actuator to provide the motive power to operate the
valve,
• positioners,
• transducers,
• supply pressure regulators,
• manual operators,
• limit switches.
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 Control Valve - Trim

Within a control valve body, the specific

components performing the work of throttling (or
completely shutting off) of fluid flow are collectively
referred to as the valve trim.

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 Control Valve

Valves can be broadly categorized based on their

functions as:
• Stop (Isolation) Valve
• Back Flow Prevention Valve (Check Valve)
• Pressure Relief Valve (Safety Valve)
• Regulating Valve

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 Types of Regulating Valves

 GATE VALVES
 GLOBE VALVES
 PLUG VALVES
 DIAPHRAGM VALVES
 BALL VALVES
 BUTTERFLY VALVES
 NEEDLE VALVES
 CHECK VALVES
 PRESSURE RELIEF VALVES

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 Gate Valves

Commonly used as the Isolation Valve 13

 Globe Valves

The flow in the valve takes a vertical path from down to top through the seat
ring, allowing effective flow control with shorter plug travel . 14
Globe Valves
In the port-guided valve, the
seat ring acts as a guide for
the plug to keep the
centerlines of the plug and
seat always aligned,
minimizing guiding stresses
that would otherwise be placed
on the stem. This means that
the stem may be made smaller
in diameter than if the valve
trim were stem-guided,
minimizing sliding friction and
improving control behavior.
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 Globe Valves

A balanced plug has one or more ports drilled from top to bottom,
allowing fluid pressure to equalize on both sides of the plug. This helps
minimize the forces acting on the plug which must be overcome by the
actuator. 16
 Globe Valves

Balanced and unbalanced cage-guided globe valves exhibit similar

characteristics to double-ported and single-ported stem- or port-guided
globe valves. Balanced cage-guided valves are easy to position, just like
double-ported stem-guided and port-guided globe valves. However,
balanced cage-guided valves tend to leak more when in the shut position
due to a greater number of leak paths, much the same as with double-
ported stem-guided and port-guided globe valves. 17
Plug Valves

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Diaphragm Valves

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Ball Valves

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Butterfly Valves

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Niddle Valves

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 Check Valves

Swing Check Valve Ball Check Valve

Check valves are designed to prevent backflow of fluid in lines. 23

Pressure Relief Valves / Safety Valves

Relief Valves Safety Valves 24

 Solenoid Valves

1. Valve Body
2. Inlet Port
3. Outlet Port
4. Coil / Solenoid
5. Coil Windings
6. Lead Wires
7. Plunger
8. Spring
9. Orifice 25
Two Port Valve

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Three Port Valve

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 Valve Packing

All stem-actuated control valves require some form of seal allowing motion of
the stem from some external device (an actuator ) while sealing process fluid
such that no leak occurs between the moving stem and the body of the
valve. The general term for this sealing mechanism is packing. 28
 Valve Seat Leakage
It is important that the control valve be able to completely stop fluid flow
when placed in the “closed” position. Although this may seem to be a
fundamental requirement of any valve, it is not necessarily so. In many
applications, there may have some allowable leakage, where as in
some other application needs tight shut-off. For this reason, several
classifications for control valves, rating them in their ability to fully shut
off are available in accordance with ANSI/FCI 70−2 and IEC 60534-4.

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 Pneumatic Actuators
The fail-safe mode of a pneumatic/spring valve is a function of both the
actuator’s action and the valve body’s action, where, upon loss of
actuating energy supply, will cause a valve closure member to be fully
closed, fully open, or remain in the last position, whichever position is
defined as necessary to protect the process.
Direct/Reverse acting Actuators:
Direct-acting actuator pushes down on the stem with increasing pressure.
Reverse-acting actuator pulls up on the stem with increasing pressure.
Direct/Reverse acting Valve Bodies:
Direct-acting if they open up when the stem is lifted.
Reverse-acting if they shut off (close) when the stem is lifted.
Thus, a sliding-stem, pneumatically actuated control valve may be made
air-to-open or air-to-close simply by matching the appropriate actuator and
body types. 30
Pneumatic Actuators

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Pneumatic Actuators

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Air To Close Valve
∆PFLOW =−
P1 P2
ΔP SHUTOFF = P1 - PLOAD
1. Usually Δ P SHUTOFF   > Δ P FLOW    
2. ΣFup = ΣFdown
P1 × Aport + Fspring + ζPacking
=PLOAD × ADiaphragm + P2 × Aplug

3. Methods to increase Δ P SHUTOFF

i) Increase PLOAD
ii) Increase ADiaphragm
iii) Reduce FSpring
iv) Reduce ζ Packing

Note: Inlet Pressure tends to push open plug

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Air To Open Valve
∆PFLOW =−
P1 P2
ΔP SHUTOFF = P1 - PLOAD
1. Usually Δ P SHUTOFF   > Δ P FLOW    
2. ΣFup = ΣFdown
P1 × Aport + PLOAD × ADiaphragm + ζPacking
= FSpring +P2 × Aplug

3. Methods to increase Δ P SHUTOFF

i) Decrease PLOAD
ii) Increase ADiaphragm
iii) Increase FSpring
iv) Reduce ζ Packing

Note: Inlet Pressure tends to push open plug

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Actuator Bench-Set

 Valve actuators provide force to move

control valve trim.
 For precise positioning of a control valve,
there must be a calibrated relationship
between applied force and valve position.
 Most pneumatic actuators exploit Hooke’s
Law to translate applied air pressure to
valve stem position:
F = kx
 The force on diaphragm of area (A) due to
actuating fluid pressure (P) is:
F = PA
 Hence
PA
= =
kx PA or x i.e. x ∞ P
k 35
 Actuator Bench-Set
 When a control valve is assembled from an actuator and a valve body, the two
mechanisms must be coupled together in such a way that the valve moves between
its fully closed and fully open positions with an expected range of air pressures (3-15
PSI).
 There are really only two mechanical adjustments that need to be made when
coupling a pneumatic diaphragm actuator to a sliding-stem valve: the stem connector
and the spring adjuster.
 The stem connector mechanically joins the sliding stems of both actuator and valve
body so they move together as one stem.
 This connector must be adjusted so neither the actuator nor the valve trim prevents
full travel of the valve trim.
 Thus stem length has been properly set by adjusting the stem connector.
 The spring adjuster is adjusted to set for the proper bench set pressure. This is the
pneumatic signal pressure required to lift the plug off the seat. For an air-
to-open control valve with a 3 to 15 PSI signal range, the “bench set”
pressure would be 3 PSI.
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Actuator Bench-Set

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 Actuator Bench-Set

If the stem connector is set with the actuator and valve stems spaced too far apart (i.e. the
total stem length is too long), the actuator diaphragm will bind travel at the upper end and
the valve plug will bind travel at the lower end. The result is a valve that cannot ever fully
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open.
 Actuator Bench-Set

If the stem connector is set with the actuator and valve stems too closely coupled (i.e. the
total stem length is too short), the actuator diaphragm will bind travel at the lower end
and the valve plug will bind travel at the upper end. The result is a valve that cannot ever
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fully close.
 Pneumatic Actuator Response
 A limitation inherent to pneumatic valve actuators is the amount of air
flow required to or from the actuator to cause rapid valve motion.
 The combined effect of air-flow friction in the tube, flow limitations
inherent to the controller mechanism, and volume inside the valve
actuator conspire to create a sluggish valve response to sudden
changes in controller output signal.

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 Pneumatic Actuator Response
 If the pneumatic valve actuator is driven by an I/P transducer instead of directly
by a pneumatic controller, the problem is lessened by the ability to locate the I/P
close to the actuator, thus greatly minimizing tube friction and thus minimizing
the “time constant” (τ ) of the control valve’s response.

 Still, if the pneumatic actuator is particularly large in volume, an I/P transducer

may experience trouble supplying the necessary air flow rate to rapidly actuate
the control valve. Certainly the problem of time delay is reduced, but not
eliminated, by the close-coupled location of the I/P transducer to the actuator. 41
 Pneumatic Actuator Response
 One way to improve valve response in either type of system (full-pneumatic
or I/P-driven) is to use a device known as a volume booster (Pneumatic
Relay) to source and vent compressed air for the valve actuator.
 A “volume booster” is a pneumatic device designed to reproduce a
pneumatic pressure signal (1:1 ratio), but with far greater output flow
capacity.
 A 3 to 15 PSI pneumatic pressure signal applied to the input of a volume
booster will result in an identical output signal (3 to 15 PSI), but with greatly
enhanced flow capacity.

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 Pneumatic Actuator Response
 A pneumatic control system equipped with a volume booster
would look something like this.

 Of course, enhanced air flow to and from the actuator does not
completely eliminate time delays in valve response. So long as
the flow rate into or out of an actuator is finite, some time will be
required to change pressure inside the actuator and thus
change valve position. 43
 Valve Positioners
 Springs work quite nicely to convert mechanical force into
mechanical motion (Hooke’s Law : F = kx) for valve actuators if
and only if the sole forces involved are the diaphragm or piston
force against the spring’s resistance force. If any other force
acts upon the system, the relationship between actuating fluid
pressure and valve stem travel will not necessarily be
proportional.
 Unfortunately, there typically are other forces acting on a valve
stem besides the actuating fluid pressure’s force and the
spring’s reaction force. Friction from the stem packing is one
force, and reaction force at the valve plug caused by differential
pressure across the plug’s area is another. These forces
conspire to re-position the valve stem so stem travel does not
precisely correlate to actuating fluid pressure.
 A common solution to this dilemma is to add a positioner to the
control valve assembly.
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 Valve Positioners
 A positioner is a motion-control device designed to actively compare
stem position against the control signal, adjusting pressure to the
actuator diaphragm or piston until the correct stem position is reached.

 Positioners essentially act as

control systems within themselves.
The valve’s stem position is the
process variable (PV), the command
signal to the positioner is the set-point
(SP), and the positioner’s signal to the valve
actuator is the manipulated variable
(MV) or output.

 The technical term for this type of control system is cascade, where one
controller’s output becomes the set-point for a different controller. In the
case of a valve positioner, the positioner receives a valve stem position
set-point from the main process controller.
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 Valve Positioners
 Inputs are:
• Supply air (usually 20PSI)
• Valve position (PV)
• A valve position (command) signal (SP)
 Either 3-15PSI or
 4-20ma

 Output is a valve position

• Actually output is air pressure to the actuator (MV)

 Control valve positioners are typically constructed in such a way to

source and vent high air flow rates, such that the positioner also
fulfills the functionality of a volume booster (that is why the positioner
needs 20 PSI air supply). Thus, a positioner not only ensures more
precise valve stem positioning, but also faster stem velocity (and
shorter time delays) than if the valve actuator were directly “powered”
by an I/P transducer.
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 Positioners Type
Force-Balance pneumatic valve positioner
The control signal for this valve is a 3 to
15 PSI pneumatic signal, coming from
either an I/P transducer or a pneumatic
controller (neither one shown in the
illustration). This control signal pressure
applies an upward force on the force
beam, such that the baffle tries to
approach the nozzle. Increasing
backpressure in the nozzle causes the
pneumatic amplifying relay to output a
greater air pressure to the valve actuator,
which in turn lifts the valve stem up
(opening up the valve). As the valve stem
lifts up, the spring connecting the force
beam to the valve stem becomes further
stretched, applying additional force to
the right-hand side of the force beam.
When this additional force balances the
bellows’ force, the system stabilizes at a 47
new equilibrium.
 Positioners Type
Motion-Balance pneumatic valve positioner
The control signal for this valve is a 3 to
15 PSI pneumatic signal, coming from
either an I/P transducer or a pneumatic
controller (neither one shown in the
illustration). In this mechanism, an
increasing signal pressure causes the
beam to advance toward the nozzle,
generating increased nozzle
backpressure which then causes the
pneumatic amplifying relay to send
more air pressure to the valve actuator.
As the valve stem lifts up, the upward
motion imparted to the right-hand end of
the beam counters the beam’s previous
advance toward the nozzle. When
equilibrium is reached, the beam will be
in an angled position with the bellows’
motion balanced by valve stem motion.
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 Positioners Type
Electronic Positioners
There are two control algorithms working
together to maintain proper valve
position: one monitoring and controlling
pressure applied to the actuator
(compensating for changes in air supply
pressure that might otherwise affect the
valve’s position) and the other monitoring
and controlling stem position itself,
sending a cascaded control signal to the
pressure control components. These two
control “loops” are sometimes referred to
as the pressure and travel loops, or the
major and minor loops, respectively.
The command signal tells the positioner where the valve stem should be positioned. The first
controller inside the positioner (PI) calculates how much air pressure at the actuator should be
needed to achieve the requested stem position. The next controller (PID) drives the I/P converter
as much as necessary to achieve that pressure. If anything causes the valve stem to not be at
the commanded position, the two controllers inside the positioner work together to force the
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valve to its proper position.
“Valve Signature” showing the behavior
of an air-to-open globe valve

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 Valve Signature
 The red graph shows the valve’s response in the opening direction where additional
pressure is required to overcome packing friction as the valve moves open (up).
 The blue graph shows the valve as it closes, less pressure applied to the diaphragm now to
allow the spring’s compression to overcome packing friction as the valve moves closed
(down) to its resting state.
 The sharp turns at each end of this graph show where the valve stem reaches its end
positions and cannot move farther despite further changes in actuator pressure.
 Each plot is roughly linear in accordance with Hooke’s Law describing the behavior of the
valve spring, Any departure from a single linear plot indicates the onset of some other
force(s) on the valve stem other than the spring’s compression. This is why we see two plots
vertically offset from each other.
 Packing friction is another force acting on the valve stem besides the spring’s compression.
 When the valve is opening, friction works against the actuator’s air pressure (assuming an
air-to-open valve), requiring additional air pressure to maintain motion. When the valve is
closing, though, packing friction works in the same direction as the actuator’s air pressure
“helping” the valve stay more open than it should. This is why the positioner must maintain
less actuator air pressure for any given position while moving closed than while the valve
moves open. The difference in air pressure moving open versus moving closed at any given
stem position is proportional to twice the dynamic packing friction. Stated mathematically,
Fpacking = (Popening − Pclosing )A.
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 Control Valve Split-Ranging

 There are many process control applications in

industry where it is desirable to have multiple
control valves respond to the output of a common
controller.
 Control valves configured to follow the command
of the same controller are said to be split-ranged,
or sequenced.
 A few different modes of control valve sequencing
are commonly seen in industry: Complementary,
Exclusive, and Progressive.

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 Complementary Valve Sequencing
 With this form of split-ranging, there is never a condition in the controller’s
output range where both valves are fully open or fully shut. Rather, each
valve complements the other’s position.

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 Complementary Valve Sequencing
 Both base and pigment valves operate from the same 3 to 15 PSI pneumatic
signal output by the I/P transducer (AY), but one of the valves is Air-To-Open
while the other is Air-To-Close.

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 Complementary Valve Sequencing
 An alternative to complementary valve sequencing in a process where two
fluid streams mix (or diverge) is to use one three-way valve rather than a pair
of two-way valves:

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 Exclusive Valve Sequencing
 With this form of valve sequencing, both valves are fully closed at a 50% controller output signal,
with one valve opening fully as the controller output drives toward 100% and the other valve
opening fully as the controller output goes to 0%.
 The nature of this valve sequencing is to have an “either-or” throttled path for process fluid. That
is, either process fluid flows through one valve or through the other, but never through both at
the same time.

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 Exclusive Valve Sequencing
 Both reagent control valves operate from the same 3 to 15 PSI pneumatic signal
output by the I/P transducer (AY), but the two valves’ calibrated ranges are not the
same.
 The Air-To-Open acid valve has an operating range of 9 to 15 PSI, while the Air-To-
Close caustic valve has an operating range of 9 to 3 PSI.

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 Progressive Valve Sequencing
 Some processes demand a greater range of control than any single valve can deliver,
and it is within these processes, a pair of progressively-sequenced control valves is a
valid solution.
 The combination of two differently-sized (small and large) control valves are used to
satisfy the process demand.

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 Progressive Valve Sequencing
 A pH control process where the incoming liquid always has a high pH value, and must
be neutralized with acid, the progressive valve sequencing may be used.

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 Flow Capacity or Flow Coefficient (Cv)
 The amount of kinetic energy represented by a volume of moving fluid in turbulent
motion with velocity v and is given by

 Hence

 When a fluid moves turbulently through any restriction, energy is inevitably

dissipated in that turbulence. The amount of energy dissipated is proportional to the
kinetic energy of the turbulent motion. i.e. the amount of energy dissipated by
turbulence in such a fluid stream will be some proportion (k) of the total kinetic
energy, so:

 Any energy lost in turbulence eventually manifests as a loss in fluid pressure

downstream of that turbulence. Thus, a control valve throttling a fluid flowstream will
have a greater upstream pressure than downstream pressure.

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 Flow Capacity or Flow Coefficient (Cv)

 This pressure drop (P1 − P2, or ΔP) is equivalent to dissipated energy per unit volume.
 With Q = Av, solving for a quotient with pressure drop (P1 − P2) in the numerator
and flow rate Q in the denominator so the equation bears a resemblance to
Ohm’s Law (R = V/I ):

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 Flow Capacity or Flow Coefficient (Cv)
 Either side of the last equation represents a sort of “Ohm’s Law” for turbulent liquid
restrictions.
 The left-hand side expressing fluid “resistance” in the state variables of pressure drop
and volumetric flow.
 The right-hand term expressing fluid “resistance” as a function of fluid density and
restriction geometry.
 We can see how pressure drop (P1 − P2) and volumetric flow rate (Q) are not linearly
related as voltage and current are for resistors, but that nevertheless we still have a
quantity that acts like a “resistance” term:

Where,
R = Fluid “resistance” P1 = Upstream fluid pressure
P2 = Downstream fluid pressure Q = Volumetric fluid flow rate
k = Turbulent energy dissipation factor ρ = Mass density of fluid
A = Cross-sectional area of restriction
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 Flow Capacity or Flow Coefficient (Cv)
 The fluid “resistance” of a restriction depends on several
variables: the proportion of kinetic energy lost due to turbulence
(k), the density of the fluid (ρ), and the cross-sectional area of the
restriction (A).
 In a control valve throttling a liquid flow stream, only k and A are
subject to change with stem position, fluid density remaining
relatively constant.
 It is customary in control valve engineering to express the
“restrictiveness” of any valve in terms of how much flow it will
pass given a certain pressure drop and fluid specific gravity (Gf ).
This measure of valve performance is called flow capacity or flow
coefficient, symbolized as Cv.
 A greater flow capacity value represents a less restrictive (less
“resistive”) valve, able to pass greater rates of flow for the same
pressure drop. 63
 Flow Capacity or Flow Coefficient (Cv)

 The first square-rooted term in the equation, is the

Valve Capacity or Cv factor. 64
 Flow Capacity or Flow Coefficient (Cv)
 Substituting Cv for this term results in the simplest form of valve
sizing equation (for incompressible fluids):

 Cv is defined as the number of US gallons of water at 600 F that

will flow per minute through a valve with 1 PSI of pressure drop.

 A similar valve capacity expression Kv used elsewhere in the

world expressed as number of cubic meters of water will flow per
hour through a valve with a pressure drop of 1 bar.

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 Control Valve Characterization
Inherent Characteristics
 When control valves are tested in a laboratory setting, they are connected to a piping
system that is able to provide a nearly constant pressure difference between upstream
and downstream (P1 − P2).
 With a fluid of constant density and a constant pressure drop across the valve, flow rate
becomes a direct function of flow coefficient (Cv ).
 The amount of “resistance” offered by a restriction of any kind to a turbulent fluid
depends on the cross-sectional area of that restriction and also the proportion of fluid
kinetic energy dissipated in turbulence.
 If a control valve is designed such that the combined effect of these two parameters vary
linearly with stem motion, the Cv of the valve will likewise be proportional to stem
position.

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 Control Valve Characterization
Installed Characteristics
 Most real valve installations do not place the control valve under a condition of constant
pressure drop.
 Due to frictional pressure losses in piping and changes in supply/demand pressures
that vary with flow rate, a typical control valve “sees” substantial changes in differential
pressure as its controlled flow rate changes.
 Generally speaking, the pressure drop available to the control valve will decrease as
flow rate increases.
 The result of this pressure drop versus flow relationship is that the actual flow rate of
the same valve installed in a real process will not linearly track valve stem position.
Instead, it will “droop” as the valve is further opened . This “drooping” graph is called
the valve’s installed characteristic.

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 Control Valve Characterization
 Let us assume the control valve has a “linear” inherent characteristic and a maximum
flow capacity (Cv rating) of 18.
 This means the valve’s Cv will be 18 at 100% open, 13.5 at 75% open, 9 at 50% open, 4.5
at 25% open, and 0 at fully closed (0% open).
 We may plot the behavior of this control valve at these four stem positions by graphing
the amount of flow through the valve for varying degrees of pressure drop across the
valve. The result is a set of characteristic curves for our hypothetical control valve.

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Control Valve Characterization
Inherent Installed

69
 Control Valve Characterization
 If we plot the valve’s performance in both scenarios we see the difference very clearly.

 The “drooping” graph shows how the valve responds when it does not receive a
constant pressure drop throughout the flow range. This is how the valve responds when
installed in a non-ideal process, compared to the straight-line response it exhibits under
ideal conditions of constant pressure.
 Any piping system that fails to provide constant pressure across a control valve will
“distort” the valve’s inherent characteristic in the same “drooping” manner, and this
must be compensated in some way if we desire linear response from the valve. 70
 Control Valve Characterization
 Note how the installed characteristic graph is relatively steep at the beginning
where the valve is nearly closed, and how the graph grows “flatter” at the end
where the valve is nearly full-open. The rate of response (rate-of-change of flow
Q compared to stem position x, which may be expressed as the derivative
(dQ/dx) is much greater at low flow rates than it is at high flow rates, all due to
diminished pressure drop at higher flow rates.
 This means the valve will respond more “sensitively” at the low end of its travel
and more “sluggishly” at the high end of its travel.
 From the perspective of a flow control system, this varying valve
responsiveness means the system will be unstable at low flow rates and
unresponsive at high flow rates.
 At low flow rates, there the valve is nearly closed, any small movement of the
valve stem will have a relatively large effect on flow. However, at high flow rates,
a much greater stem motion will be required to effect the same change in flow.
 Thus, the control system will tend to over-react at low flow rates and under-
react at high flow rates, simply because the control valve fails to exert the same
degree of control over process flow at different flow rates.
71
 Characterized Valve Trim
 The root cause of the problem – a varying pressure drop caused by frictional losses in
the piping and other factors – generally cannot be eliminated.
 However, there is a clever way to to purposely design the valve such that its inherent
characteristic complements the process “distortion” caused by changing pressure drop.
 In other words, we design the control valve trim so it opens up gradually during the
initial stem travel (near the closed position), then opens up more rapidly during the final
stages of stem travel (near the full-open position).
 With the valve made to open up in a nonlinear fashion inverse to the “droop” caused by
the installed pressure changes, the two non-linearities should cancel each other and
yield a more linear response.
 This re-design will give the valve a nonlinear characteristic when tested in the laboratory
with constant pressure drop, but the installed behavior should be more linear.

72
 Valve Trim Characteristics
 Control valve trim is manufactured in a variety of different inherent “characteristics” to
provide the desired installed behavior.

Quick-opening
Linear
Equal percentage

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 Valve Trim Characteristics
 Quick-opening
The quick−opening flow characteristic provides for maximum
change in flow rate at low valve travels with a nearly linear
relationship. Additional increases in valve travel give sharply
reduced changes in flow rate, and when the valve plug nears the
wide open position, the change in flow rate approaches zero.
Applications:
 On/off applications where
significant flow rate must be
established quickly as the valve
begins to open. consequently,
they are often used in relief valve
applications.

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 Valve Trim Characteristics
 Linear
The linear flow characteristic curve shows that the flow rate is
directly proportional to the valve travel. This proportional
relationship produces a characteristic with a constant slope so
that with constant pressure drop, the valve gain will be the same
at all flows throughout the travel range.
Applications:
 Valves with a linear
characteristic are often specified
for liquid level control and for flow
control applications requiring
constant gain.

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 Valve Trim Characteristics
 Equal Percentage
Ideally, for equal increments of valve plug travel, the change in
flow rate regarding travel may be expressed as a constant percent
of the flow rate at the time of the change.

Applications:
 Pressure control applications,
on applications where a large
percentage of the pressure drop is
normally absorbed by the system
itself with only a relatively small
percentage available at the control
valve and on applications where
highly varying pressure drop
conditions can be expected. 76
 Valve Trim Characteristics
 Equal Percentage
e( lnτ ) H  Qmax controllable 
Q = Qmax ; where,τ ValveRangeability   ,
τ 
 Qmin controllable 
H Valve Lift = =
(0 close ,1 fully open);=
Qmax Max. vol. flow through valve.

Qmax = 10 m3/hr
τ=50

77
 Valve Trim Characteristics

Plug Profiles Of A Single-ported, Stem-guided Globe Valve

78
 Valve Sizing
 STEP 1: Define the system

The system is pumping water from one tank to another through a

piping system with a total pressure drop of 150 psi. The fluid is water
at 70 0F. Design (maximum) flowrate of 150 gpm, operating flowrate
of 110 gpm, and a minimum flowrate of 25 gpm. The pipe diameter is
3 inches. At 70 0F, water has a specific gravity of 1.0.

Key Variables: Total pressure drop, design flow, operating flow,

minimum flow, pipe diameter, specific gravity

79
 Valve Sizing
 STEP 2: Define a maximum allowable pressure drop for the valve

The usual rule of thumb is that a valve should be designed to use 10-
15% of the total pressure drop or 10 psi, whichever is greater.
For our system, 10% of the total pressure drop is 15 psi which is what
we'll use as our allowable pressure drop when the valve is wide open.

 STEP 3: Calculate the valve characteristic

For our system,

80
 Valve Sizing
 STEP 4: Preliminary valve selection
 Don't make the mistake of trying to match a valve with your
calculated Cv value. The Cv value should be used as a guide
in the valve selection, not a hard and fast rule.
 Some other considerations are:
 Never use a valve that is less than half the pipe size,
 Avoid using the lower 10% and upper 20% of the valve stroke. The
valve is much easier to control in the 10-80% stroke range.

Before a valve can be selected, decide what type of valve will be used.

For our case, we'll assume we're using an equal percentage,

globe valve. The valve chart for this type of valve is shown
below.
81
 Valve Sizing
 STEP 4: Preliminary valve selection

For our case, it appears the 2 inch valve will work well for our Cv value at about 80-85% of
the stroke range. Notice that we're not trying to squeeze our Cv into the 1 1/2 valve which
would need to be at 100% stroke to handle our maximum flow.
82
 Valve Sizing
 STEP 5: Check the Cv and stroke percentage at the minimum flow
Cv at minimum flowrate:

Referring back to our valve chart, we see that a Cv of 6.5 would correspond
to a stroke percentage of around 35-40% which is certainly acceptable.

Notice that we used the maximum pressure drop of 15 psi once again in our
calculation. Although the pressure drop across the valve will be lower at
smaller flowrates, using the maximum value gives us a "worst case"
scenario. If our Cv at the minimum flow would have been around 1.5, there
would not really be a problem because the valve has a Cv of 1.66 at 10% stroke
and since we use the maximum pressure drop, our estimate is
conservative. Essentially, at lower pressure drops, Cv would only increase
which in this case would be advantageous.

83
 Valve Sizing
 STEP 6: Check the gain across applicable flow rates
Gain is defined as:
Now, at our three flow rates:
Qmin = 25 gpm
Qop = 110 gpm
Qdes = 150 gpm
We have corresponding Cv values of 6.5, 28, and 39. The corresponding stroke percentages
are 35%, 73%, and 85% respectively. Now we construct the following table:
Flow Stroke Change in flow
Change in Stroke (%)
(gpm) (%) (gpm)
25 35
110-25 = 85 73-35 = 38
110 73
150 85
150-110 = 40 85-73 = 12

Gain #1 = 85/38 = 2.2

Gain #2 = 40/12 = 3.3
The difference between these values should be less than 50% of the higher value.
0.5 of 3.3 = 1.65 and 3.3 - 2.2 = 1.10.
Since 1.10 is less than 1.65, there should be no problem in controlling the valve. Also note
that the gain should never be less than 0.50. So for our case, our selected valve will do
nicely!
84
 Valve Selection
 Equal Percentage: equal increments of valve travel produce an equal percentage
in flow change.
Linear: valve travel is directly proportional to the valve stoke.
Quick opening: large increase in flow with a small change in valve stroke.

 So how do you decide which valve control to use? 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.) 85
 Control Valve Problems

 Mechanical Friction
 Flashing
 Cavitation
 Choked flow
 Valve noise
 Erosion
 Chemical Attack

86
 Control Valve Problems
Mechanical Friction
 Control valves are mechanical devices having moving parts, and as such
they are subject to friction (static or dynamic), primarily between the
valve stem and the stem packing.
 The presence of packing friction in a control valve increases the force
necessary from the actuator to cause valve movement.
 Instead of the stem smoothly lifting immediately as pressure exceeds
the bench-set value, the valve will remain fully closed until enough extra
pressure has accumulated in the actuator to generate a force large
enough to overcome spring tension plus packing friction.
 Effect of static and dynamic friction induces “slip-stick” response of the
stem motion.
 In order to reverse the direction of stem motion, not only does the static
friction have to be “relaxed” from the last movement, but additional
static friction must be overcome in the opposite direction before the
stem is able to move that way.
87
 Control Valve Problems
Mechanical Friction
 To use numerical quantities, if pressure increments of 0.5 PSI are
required to repeatedly overcome static friction in the upward (opening)
direction, a pressure decrement of approximately twice that (1.0 PSI) will
be required to make the stem go downward even just a bit.

88
 Control Valve Problems
Mechanical Friction

89
 Control Valve Problems
Flashing
 If the fluid being throttled by the valve is a liquid and its
absolute pressure ever falls below the vapor pressure of that
substance, the liquid will begin to boil. This phenomenon, when
it happens inside a control valve, is called Flashing.

 As the graph shows, the

point of lowest pressure
inside the valve (called the
vena contracta pressure, or
Pvc) is the location where
flashing will first occur, if it
occurs at all.
90
 Control Valve Problems
Flashing
 The effect of boiling liquid at the point of maximum constriction is that flow
through the valve becomes “choked” by the rapid expansion of liquid to
vapor as it boils, severely inhibiting the total flow rate allowed through the
valve.
 Flashing is also destructive to the valve trim, as boiling action propels tiny
droplets of liquid at extremely high velocities past the plug and seat faces,
eroding the metal over time.
 Pressure recovery is the amount that fluid pressure increases from the
minimum pressure at the vena contracta to the downstream pressure:
P2 − Pvc.
 Pressure Recovery Factor

Where,
FL = Pressure recovery factor (unit less)
P1 = Absolute fluid pressure upstream of the valve
P2 = Absolute fluid pressure downstream of the valve
Pvc = Absolute fluid pressure at the vena contracta (point of minimum fluid
pressure within the valve) 91
 Control Valve Problems
Flashing
 The style of valve (ball, butterfly, globe, etc.) is very influential on pressure recovery
factor.

 The globe valve does a better job of evenly distributing pressure losses throughout
the path of flow. By contrast, the butterfly valve can only drop pressure at the points
of constriction between the disk and the valve body, because the rest of the valve
body is a straight-through path for fluid offering little restriction at all. As a
consequence, the butterfly valve experiences a much lower vena contracta pressure
(i.e. greater pressure recovery, and a lower FL value) than the globe valve for any
given amount of permanent pressure loss, making the butterfly valve more prone to
flashing than the globe valve with all other factors being equal. 92
 Control Valve Problems
Cavitation
 If, the pressure recovers to a point greater than the vapor pressure of
the liquid, the vapor will re-condense back into liquid again. This is
called Cavitation.
 When vapor bubbles re-condense into liquid they often do so
asymmetrically, one side of the bubble collapsing before the rest of
the bubble. This has the effect of translating the kinetic energy of the
bubble’s collapse into a high-speed “jet” of liquid in the direction of
the asymmetrical collapse.
 These liquid “microjets” have been experimentally measured at
speeds up to 100 meters per second (over 320 feet per second).
 Each microjet strikes the valve component surface over a very small
surface area, resulting in a very high pressure (P = F/A) applied to that
small area.
 The effect of each microjet impinging on a metal surface is to carve
out a small pocket in that metal surface. Over time, the metal will
begin to take on a “pock-marked” look over the area where cavitation
occurs.
93
 Control Valve Problems
Photographs of a fluted valve plug and its matching seat are shown here as
evidence of flashing and cavitation damage, respectively:

 The flashing damage is responsible for the relatively smooth wear areas
seen on the plug.
 Cavitation damage is most prominent inside the seat, where almost all the
damage is in the form of pitting.
 The mouth of the seat exhibits smooth wear caused by flashing, but deeper
inside you can see the pock-marked surface characteristic of cavitation,
where liquid microjets literally blasted away pieces of metal. 94
 Control Valve Problems
 Flashing sounds as though sand were flowing through the valve, cavitation
produces a much louder “crackling” sound comprised of distinct impact
pulses, reminiscent of what gravel or rocks might sound like if they were
somehow forced to flow through the valve.

95
 Control Valve Problems
Cavitation-control valve trim:
 Valve trim may be specially designed for cavitation abatement by providing
multiple stages of pressure drop for the fluid as it passes through the trim.
 A valve equipped with cavitation-control trim will have a different pressure
profile, with multiple vena contracta points where the fluid passes through a
series of constrictions within the trim itself.
 This way, the same final permanent pressure drop (P1 −P2) may be achieved
without the lowest pressure ever falling below the liquid’s vapor pressure limit.

96
 Control Valve Problems
Choked Flow
 “Choked flow” is a condition where the rate of flow through a valve does not
change substantially as downstream pressure is reduced.
 Choking occurs when the velocity of the fluid reaches the speed of sound for
that fluid.
 Pressure changes propagate through any fluid at the speed of sound within
that fluid.
 If a fluid stream happens to move at or above the speed of sound, pressure
changes downstream are simply not able to overcome the stream’s velocity to
affect anything upstream, which explains why the flow rate through a control
valve experiencing sonic (critical) flow velocities does not change with
changes in downstream pressure: those downstream pressure changes cannot
propagate upstream against the fast-moving flow, and so will have no effect on
the flow as it accelerates to sonic velocity at the point(s) of constriction.

97
 Control Valve Problems
Choked Flow

 In a choked flow condition, further reductions in downstream pressure achieve

no greater flow of liquid through the valve. This is not to say that the valve has
reached a maximum flow – we may still increase flow rate through a choked
valve by increasing its upstream pressure. We simply cannot coax more flow
through a choked valve by decreasing its downstream pressure. 98
 Control Valve Problems
Valve Noise
 Noise produced due to the phenomenon of flashing, cavitation and sonic flow.
 One way to reduce noise output is to use special valve trim resembling the trim
used to mitigate cavitation.
 A common cage-guided globe valve trim design for noise reduction uses a
special cage designed with numerous, small holes for process gas to flow
through. These small holes shift the frequency of that noise up above the
human hearing range.

99
 Control Valve Problems
Erosion

A problem common to control valves used in slurry service (where the process
fluid is a liquid containing a substantial quantity of hard, solid particles) is
erosion, where the valve trim and body are worn by the passage of solid
particles.

Chemical attack

Corrosive chemicals may attack the metal components of control valves if

those components are not carefully selected for the proper service.

100
 References

 R. Kuphaldt, “Lessons In Industrial Instrumentation”, Version

1.14, January 11, 2011.
 Control Valve Handbook, Fourth Edition, Fisher Controls
International , 2005.
 Classification Of Valves, PPT, M. Ganesh Murugan.

101
Thank You

102