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Process Control Valve Engineering

Control valve Info

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100% found this document useful (4 votes)

644 views

Process Control Valve Engineering

Control valve Info

Uploaded by

RAMSAHARE MALLAH

Available Formats

Download as PDF, TXT or read online on Scribd

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PROCESS CONTROL VALVE

ENGINEERING

ENG / ISLAM DEIF

 Control Valve Types

 Actuators types

 Valve Accessories

 Phenomena Associated to the Control Valve

 Valve Selection and Sizing

 Testing and Installation

© 2014 / CONFIDENTIAL ISLAM DEIF 3

CONTROL VALVE TERMINOLOGY
CONTROL VALVE
 A power actuated device which modifies the fluid flow rate in a process
control system. It consists of a valve connected to an actuator mechanism
(including all related accessories) that is capable of changing the position
of a closure member in the valve in response to a signal from the
controlling system.
 Control valve is considered the most important final control element in a
process control loops

© 2014 / CONFIDENTIAL ISLAM DEIF 4

CONTROL VALVE TERMINOLOGY

BASIC CONTROL LOOP

There are 2 types of control loops

 Open-Loop Control System
 Closed-Loop Control System

© 2014 / CONFIDENTIAL ISLAM DEIF 5

CONTROL VALVE TERMINOLOGY
CONTROL VALVE GAIN
 The change in the flow rate as a function of the change in valve travel. It
is the slope of the installed flow characteristic curve.

© 2014 / CONFIDENTIAL ISLAM DEIF 6

CONTROL VALVE TERMINOLOGY
HYSTERESIS
 The maximum difference in output value for any single input value during
a calibration cycle, excluding errors due to dead band.

© 2014 / CONFIDENTIAL ISLAM DEIF 7

CONTROL VALVE TERMINOLOGY
DEAD BAND (BACKLASH)
 The range through which an input signal can be varied, upon reversal of
direction, without initiating an observable change in the output signal.
Dead band is the name given to a general phenomenon that can apply to
any device. For the valve assembly, the controller output (CO) is the input
to the valve assembly and the process variable (PV) is the output of the
control valve .

© 2014 / CONFIDENTIAL ISLAM DEIF 8

CONTROL VALVE TERMINOLOGY
HYSTERESIS & DEAD BAND EFFECTS

© 2014 / CONFIDENTIAL ISLAM DEIF 9

CONTROL VALVE TERMINOLOGY
LINEARITY
 The closeness to which a curve relating to two variables approximates a
straight line. (Linearity also means that the same straight line will apply for
both upscale and downscale directions. Thus, dead band as defined above,
would typically be considered a non-linearity)

© 2014 / CONFIDENTIAL ISLAM DEIF 10

CONTROL VALVE TERMINOLOGY
Rangeability
 The ratio of the largest flow coefficient (Cv or Kv) to the smallest
controllable flow coefficient (Cv or Kv) within which the deviation from
the specified flow characteristic does not exceed the stated limits.

Turndown
 Turndown applies to the application and is the ratio of the calculated Cv
at maximum conditions to the calculated Cv at minimum.

© 2014 / CONFIDENTIAL ISLAM DEIF 11

CONTROL VALVE TERMINOLOGY
ACCURACY
 the degree of conformity of an indicated value to a recognized accepted
standard value or ideal value.

REPEATABILITY
 The closeness of agreement among a number of consecutive
measurements of the output for the same value of input under the same
operating conditions, approaching from the same direction, for full range
traverses. It does not include hysteresis.

© 2014 / CONFIDENTIAL ISLAM DEIF 12

CONTROL VALVE TERMINOLOGY
LOOP GAIN:
 The combined gain of all the components in the loop when viewed in
series around the loop Sometimes referred to as open-loop gain.

RESOLUTION:
 The minimum possible change in input required to produce a detectable
change in the output when no reversal of the input takes place.
Resolution is typically expressed as a percent of the input span.

© 2014 / CONFIDENTIAL ISLAM DEIF 13

CONTROL VALVE TERMINOLOGY
Dead Time
 The time interval (Td) in which no response of the system is detected
following a small (usually 0.25% - 5%) step input. It is measured from the
time the step input is initiated to the first detectable response of the
system being tested. Dead Time can apply to a valve assembly or to the
entire process

DRIFT
 An undesired change in the output/input relationship over a period of
time.

CAPACITY (VALVE)
 The rate of flow through a valve under stated conditions (CV).

© 2014 / CONFIDENTIAL ISLAM DEIF 14

CONTROL VALVE TERMINOLOGY
FRICTION
 A force that tends to oppose the relative motion between two surfaces
that are in contact with each other. The friction force is a function of the
normal force holding these two surfaces together and the characteristic
nature of the two surfaces. Friction has two components: static friction
and dynamic friction. Static friction is the force that must be overcome
before there is any relative motion between the two surfaces. Once
relative movement has begun, dynamic friction is the force that must be
overcome to maintain the relative motion.

“Stiction” is terms that are sometimes used to describe static friction.

© 2014 / CONFIDENTIAL ISLAM DEIF 15

CONTROL VALVE TERMINOLOGY
Principles of valve throttling processes
 A control valve modifies the fluid flow rate in a process pipeline by
providing a means to change the effective cross sectional area at the
valve.

 This in turn forces the fluid to increase its velocity as passes through the
restriction. Even though it slows down again after leaving the valve, some
of the energy in the fluid is dissipated through flow separation effects and
frictional losses, leaving a reduced pressure in the fluid downstream of the
valve.

© 2014 / CONFIDENTIAL ISLAM DEIF 16

CONTROL VALVE TERMINOLOGY
Principles of valve throttling processes

 To display the general behavior of flow through a control valve the valve is
simplified to an orifice in a pipeline as shown in Figure

© 2014 / CONFIDENTIAL ISLAM DEIF 17

CONTROL VALVE TERMINOLOGY
Principles of valve throttling processes

 it is important to understandhow the pressure conditions change In the

fluid as it passes through the restriction and the vena contracta and then
how the pressure partially recovers as the fluid enters the downstream
pipe area.

 The first point to note is that the velocity of the fluid must increase as
the flow area decreases.

This is given by the continuity of flow equation;

V1.A1=V2.A2

© 2014 / CONFIDENTIAL ISLAM DEIF 18

CONTROL VALVE TERMINOLOGY
Principles of valve throttling processes

 Now to consider the pressure conditions we apply Bernoulli's equation

,which demonstrates the balance between dynamic, hydrostatic pressure
and Static. Energy must be balanced each side of the flow restriction so
that:

© 2014 / CONFIDENTIAL ISLAM DEIF 19

CONTROL VALVE TERMINOLOGY
Principles of valve throttling processes

© 2014 / CONFIDENTIAL ISLAM DEIF 20

CONTROL VALVE STANDARDS
Control Valve Standards
 Numerous standards are applicable to control valves. International and
global standards are becoming increasingly important for companies that
participate in global markets. Following is a list of codes and standards
that have been or will be important in the design and application of
control valves.

 It covers the following issues

1-face to face dimensions.
2-Materials of construction.
3-Pressure-temperature ratings.
4-Design of some components to ensure adequate strength.
5-Testing procedures.

© 2014 / CONFIDENTIAL ISLAM DEIF 21

CONTROL VALVE STANDARDS
Well Known Valve Standards
ISA Instrument Society of America

ASME American Society of Mechanical Engineers

CEN European Committee for Standardization

API American Petroleum Institute

IEC International Electrotechnical Commission

ISO International Standards

Organization

ANSI American National Standards Institute

© 2014 / CONFIDENTIAL ISLAM DEIF 22

CONTROL VALVE STANDARDS
Instrument Society of America (ISA)
S51.1, Process Instrumentation Terminology
S75.01, Flow Equations for Sizing Control Valves
S75.02, Control Valve Capacity Test Procedures
S75.03, Face-to-Face Dimensions for Flanged Globe-Style Control Valve Bodies
(Classes 125, 150, 250, 300, and 600)
S75.04, Face-to-Face Dimensions for Flangeless Control Valves (Classes
150, 300, and 600)
S75.05,Terminology
S75.07, Laboratory Measurement of Aerodynamic Noise Generated by
Control Valves
S75.08, Installed Face-to-Face Dimensions for Flanged Clamp or Pinch Valves
S75.11, Inherent Flow Characteristic and Rangeability of Control Valves
S75.12, Face-to-Face Dimensions for Socket Weld-End and Screwed-End
Globe-Style Control Valves (Classes150, 300, 600, 900, 1500, and 2500)
S75.13, Method of Evaluating the Performance of Positioners with Analog
Input Signals

© 2014 / CONFIDENTIAL ISLAM DEIF 23

CONTROL VALVE STANDARDS
Instrument Society of America (ISA)
S75.14, Face-to-Face Dimensions for Buttweld-End Globe-Style Control
Valves (Class 4500)
S75.15, Face-to-Face Dimensions for Buttweld-End Globe-Style Control
Valves (Classes 150, 300, 600, 900, 1500, and 2500)
S75.16, Face-to-Face Dimensions for Flanged Globe-Style Control Valve
Bodies (Classes 900, 1500, and 2500)
S75.17, Control Valve Aerodynamic Noise Prediction
S75.19, Hydrostatic Testing of Control Valves
S75.20, Face-to-Face Dimensions for Separable Flanged Globe-Style Control
Valves (Classes 150, 300, and 600)
S75.22, Face-to-Centerline Dimensions for Flanged Globe-Style Angle Control
Valve Bodies (Classes 150, 300, and 600)
RP75.23, Considerations for Evaluating Control Valve Cavitation

© 2014 / CONFIDENTIAL ISLAM DEIF 24

CONTROL VALVE STANDARDS
ANSI -American National Standards Institute

© 2014 / CONFIDENTIAL ISLAM DEIF 25

CONTROL VALVE STANDARDS
API - American Petroleum Institute

© 2014 / CONFIDENTIAL ISLAM DEIF 26

CONTROL VALVE STANDARDS
ASME-American Society of Mechanical Engineers

NACE-National Association of Corrosion Engineers

© 2014 / CONFIDENTIAL ISLAM DEIF 27

CONTROL VALVE
COMPONENTS

© 2014 / CONFIDENTIAL ISLAM DEIF 28

CONTROL VALVE COMPONENTS

Actuator

Accessories

Body

© 2014 / CONFIDENTIAL ISLAM DEIF 29

CONTROL VALVE COMPONENTS
Basic Valve Components

 BODY

 BONNET

 TRIM

 PACKING

 ACTUATOR

© 2014 / CONFIDENTIAL ISLAM DEIF 30

CONTROL VALVE COMPONENTS
Body
 Is the main part of the valve. All other parts fit onto the body.
 It is usually cast or forged and the shape varies with the type of valve.
 Inlet and outlet pipes fit onto the valve body through threaded, bolted
(flanged) or welded joints.
 The fluid passes through the valve body when the valve is open.
 The valve body must be strong enough to take the maximum pressure of
the process fluid. It must also be made of a material that is not attacked
by the fluid.

Bonnet
 Is a removable cover fitted to the body. Some bonnets support the
moving parts of the valve. Others just close the hole in the body through
which the moving parts pass for assembly and dismantling.

© 2014 / CONFIDENTIAL ISLAM DEIF 31

CONTROL VALVE COMPONENTS
Trim (Plug and Seat )
Is the name given to the parts inside a valve. This normally includes:
 The opening/closing element—closes the fluid path through the valve
body
 The valve stem—connects the actuator to the closing element
 The valve seat—makes a seal with the closing element when the valve is
closed

Packing
 It allows the valve stem to pass into the valve body without loss of fluid
or fluid pressure from the valve. It forms a dynamic seal between the
valve stem and the bonnet.

Actuator
 Operates the stem and closing element assembly.

© 2014 / CONFIDENTIAL ISLAM DEIF 32

CONTROL VALVE COMPONENTS
End Connections
Must be specified when buying the valve – butt weld end, compression flange,
pipe thread, quick disconnect

© 2014 / CONFIDENTIAL ISLAM DEIF 33

CONTROL VALVE COMPONENTS
End Connections

© 2014 / CONFIDENTIAL ISLAM DEIF 34

CONTROL VALVE COMPONENTS

© 2014 / CONFIDENTIAL ISLAM DEIF 35

CONTROL VALVE COMPONENTS
End Connecions

© 2014 / CONFIDENTIAL ISLAM DEIF 36

CONTROL VALVE
BODY

© 2014 / CONFIDENTIAL ISLAM DEIF 37

CONTROL VALVE BODY
Control Valve Classification

Control
Valve

Linear Rotary
Motion Motion

Globe Diaphragm Gate Ball Butterfly Disk

Globe Angle 3 way

Single Double
port port

© 2014 / CONFIDENTIAL ISLAM DEIF 38

CONTROL VALVE BODY
LINEAR (SLIDING STEM VALVES )
A sliding-stem valve body is one where the moving parts slide with a linear
motion.

Main types of linear valves :

 Globe Valves
 Diaphragm Valves
 Gate Valves

© 2014 / CONFIDENTIAL ISLAM DEIF 39

CONTROL VALVE BODY
Globe Valves
 Globe valves restrict the flow of fluid by altering the distance between a
movable plug and a stationary seat (in some cases, a pair of plugs and
matching seats). 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. The globe
valve design is one of the most popular sliding-stem valve designs used in
throttling service.

© 2014 / CONFIDENTIAL ISLAM DEIF 40

CONTROL VALVE BODY
SINGLE-PORTED GLOBE
 Large amount of force required to drive the stem

 Tight shut off

 Used in small diameter applications

© 2014 / CONFIDENTIAL ISLAM DEIF 41

CONTROL VALVE BODY
DOUBLE-PORTED GLOBE VALVE
 The purpose of a double-ported
globe valve is to minimize the force
applied to the stem by process fluid
pressure across the plugs which
comes in trade of tight shutoff of the
valve

© 2014 / CONFIDENTIAL ISLAM DEIF 42

CONTROL VALVE BODY

Application
Throttling general purpose flow control valve

Advantages Disadvantages
Faster than gate, seat less wear and High pressure drop, require
tear, high pressure drop for pressure considerable power to operate
control. (gears and levers), heavy.
Minimizes disassembly for Valves cannot be welded in-line
maintenance. since the valve body is required to
Streamlined flow path with a be split.
minimum of parts and no irregular
cavities.

© 2014 / CONFIDENTIAL ISLAM DEIF 43

CONTROL VALVE BODY
3-WAY VALVES
 Three-way valves are useful in services where a flow stream must be
diverted (split) between two different directions, or where two flow
streams must converge (mix) within the valve to form a single flow
stream.

© 2014 / CONFIDENTIAL ISLAM DEIF 44

CONTROL VALVE BODY
ANGLE VALVES
 The inlet and outlet ports are at
right angle to each other .

 Can be installed in case of no

inline globe valve can be installed

© 2014 / CONFIDENTIAL ISLAM DEIF 45

CONTROL VALVE BODY
Z GLOBE VALVE
 The name is given because of the path the fluid has to take as it passes
through the valve. It changes direction twice, like the letter Z.
 Z-type globe valves are used mainly for small-size, low-pressure
applications. In large, high-pressure lines, the changes of flow direction
cause a large pressure drop and turbulence that can damage the trim.

© 2014 / CONFIDENTIAL ISLAM DEIF 46

CONTROL VALVE BODY
Y GLOBE VALVE
 Having the seat at about 45 to the flow direction straightens the flow
path and reduces the pressure drop. This type of valve can be used for
high-pressure applications.
 Have the property of self drain useful in high temperature application

© 2014 / CONFIDENTIAL ISLAM DEIF 47

CONTROL VALVE BODY
DIAPHRAGM VALVE
 Diaphragm valves use a flexible sheet
pressed close to the edge of a solid dam
to narrow the flow path for fluid. These
valves are well suited for flows
containing solid particulate matter such
as slurries.
 Precise throttling may be difficult to
achieve due to the elasticity of the
diaphragm.
 This diaphragm completely separates
the valve trim from the fluid flowing
through the valve. This means that the
fluid does not contact the trim and the
stem does not need any gland packing.

© 2014 / CONFIDENTIAL ISLAM DEIF 48

CONTROL VALVE BODY
DIAPHRAGM VALVE ASSEMBLY

© 2014 / CONFIDENTIAL ISLAM DEIF 49

CONTROL VALVE BODY
Diaphragm Valve positions (on-off)

© 2014 / CONFIDENTIAL ISLAM DEIF 50

CONTROL VALVE BODY
DIAPHRAGM VALVE POSITIONS (THROTTLING)

© 2014 / CONFIDENTIAL ISLAM DEIF 51

CONTROL VALVE BODY

Application
Used for biochemical processes. used for regulation of most gases and
liquids

Advantages Disadvantages
Valve components can be isolated The diaphragm becomes worn
from the process fluid. more easily and regular
Valve construction prevents leakage maintenance is necessary.
ofthe fluid without the These types of valves are generally
use of a gland seal (packing) not suited for very high
temperature fluids and are mainly
used on liquid systems.

© 2014 / CONFIDENTIAL ISLAM DEIF 52

CONTROL VALVE BODY
GATE VALVE
 Gate valves work by inserting a dam (gate) into
the path of the flow to restrict it, in a manner
similar to the action of a sliding door. Gate
valves are more often used for on/off control
than for throttling.

© 2014 / CONFIDENTIAL ISLAM DEIF 53

CONTROL VALVE BODY
Rising and Non Rising stem

© 2014 / CONFIDENTIAL ISLAM DEIF 54

CONTROL VALVE BODY
GATE VALVE WITH HANDWHEEL
 Turning the hand wheel raises and lowers the gate.
 When the gate valve is fully closed, the gate fills the passage and stops the
flow through the valve completely.
 When the valve is fully opened, the gate is positioned above the passage
in the valve body. This allows full flow through the valve, with little or no
obstruction.There is very little pressure drop across the valve.

© 2014 / CONFIDENTIAL ISLAM DEIF 55

CONTROL VALVE BODY

Application
stop valves, (not throttling), high pressure and temp, not for slurries,
viscous fluids

Advantages Disadvantages
low pressure drop when fully open, vibration when partially open, slow
tight seal when closed, free of response and large actuating force
contamination buildup.

© 2014 / CONFIDENTIAL ISLAM DEIF 56

CONTROL VALVE BODY
Knife Gate valve
 Knife gate valves, have a simple, one-piece closing element. It is a parallel-
sided plate that may move clear of the flow path to open or may have a
hole that moves into the flow path.

© 2014 / CONFIDENTIAL ISLAM DEIF 57

CONTROL VALVE BODY
ROTARY VALVES
 A different strategy for controlling the flow of fluid is to insert a rotary
element into the flow path. Instead of sliding a stem into and out of the
valve body to actuate a throttling mechanism, rotary valves rely on the
rotation of a shaft to actuate the trim. An important advantage of rotary
control valves over sliding-stem designs such as the globe valve and
diaphragm valve is a virtually obstruction less path for fluid when the
valve is wide-open.

MAIN TYPES OF ROTARY VALVES

 Ball Valves
 Butterfly Valves
 Disc Valves

© 2014 / CONFIDENTIAL ISLAM DEIF 58

CONTROL VALVE BODY
BALL VALVE
 In the ball valve design, a spherical ball with a passageway cut through the
center rotates to allow fluid more or less access to the passageway. When
the passageway is parallel to the direction of fluid motion, the valve is
wide open; when the passageway is aligned perpendicular to the direction
of fluid motion, the valve is fully shut (closed).

© 2014 / CONFIDENTIAL ISLAM DEIF 59

CONTROL VALVE BODY
BALL VALVES OPEN / CLOSE STATES

CLOSE OPEN

© 2014 / CONFIDENTIAL ISLAM DEIF 60

CONTROL VALVE BODY

Application
Flow control, pressure control, shutoff, corrosive fluids, liquids gases,
high temp.

Advantages Disadvantages
Low pressure drop, low leakage, Seat can wear if used for throttling,
small, rapid opening. quick open may cause hammer.
Low cost and weight relative to Over sizing.
globes as size increases High cost in large sizes compared to
High flow capacities (2 to 3 times butterfly valves.
that of globe valves)
Tight shutoff
Low stem leakage
Easily fitted with quarter turn
actuators

© 2014 / CONFIDENTIAL ISLAM DEIF 61

CONTROL VALVE BODY
BUTTERFLY VALVES
Butterfly valves are quite simple to understand:
the “butterfly” element is a disk that rotates
perpendicular to the path of fluid flow. When
parallel to the axis of flow, the disk presents
minimal obstruction; when perpendicular to the
axis, the disk completely blocks any flow. Fluid-tight
shutoff is difficult to obtain in the classic butterfly
design unless the seating area is lined with a soft
(elastic) material.
The disc turns to open and close the valve. The disc or seat may be made of
a polymer (plastic) to give a better seal.

Butterfly valves are simple and take up little space. This makes them
especially good for use in large pipelines or where there is not much space.
Operating a butterfly valve can take a lot of force as you have to push it against
the fluid pressure. Larger valves usually have geared actuators to make
operation easier.
© 2014 / CONFIDENTIAL ISLAM DEIF 62
CONTROL VALVE BODY
BUTTERFLY POSITIONS

© 2014 / CONFIDENTIAL ISLAM DEIF 63

CONTROL VALVE BODY
BUTTERFLY POSITIONS
 Most butterfly discs turn on a stem that passes through the center of the
disc along a diameter. When the valve is closed, fluid pressure pushes
equally on both sides of the stem: half the force is pushing in the closing
direction and half in the opening direction

© 2014 / CONFIDENTIAL ISLAM DEIF 64

CONTROL VALVE BODY

Application
Low pressure, large diameter lines where leakage is unimportant

Advantages Disadvantages
Low pressure drop, small and High leakage, high actuation forces
lightweight. so limited to low pressures.
Low cost and weight relative to Over sizing
globes as size increases
High flow capacities
Low stem leakage

© 2014 / CONFIDENTIAL ISLAM DEIF 65

CONTROL VALVE BODY
DISC VALVE
 Disk valves (often referred to as eccentric disk valves, or as high-
performance butterfly valves) are a variation on the butterfly design
intended to improve seat shut-off. The disk’s center is offset from the
shaft centerline, causing it to approach the seat with a “cam” action that
results in high seating pressure. Thus, tight shut-off of flow is possible even
when using metal seats and disks.

© 2014 / CONFIDENTIAL ISLAM DEIF 66

SPECIAL VALVES

© 2014 / CONFIDENTIAL ISLAM DEIF 67

SPECIAL VALVES
Pressure relief valves
 Pressure relief valves are used mainly to
relieve overpressure of liquids. This often
happens when a liquid in a closed container
or pipeline expands as its temperature
increases.
 Under normal operating conditions, a spring
holds the PRV closed. Fluid pressure pushes
against the spring to open the valve. The
fluid pressure needed to push the valve
open is called the set point pressure. The
set point pressure is usually the maximum
normal operating pressure of the liquid.

© 2014 / CONFIDENTIAL ISLAM DEIF 68

SPECIAL VALVES
Pressure relief valves
 An adjustment screw changes the spring force for different set point
pressures. When the liquid pressure exceeds the set point pressure, the
valve opens slowly. It releases just enough liquid to bring the pressure
down to the normal operating pressure. The spring then closes the valve
slowly so that normal operations can continue.

© 2014 / CONFIDENTIAL ISLAM DEIF 69

SPECIAL VALVES
Pressure safety valves
 Pressure safety valves are used mainly to
relieve overpressure of gases and vapors
(e.g. steam). The set point pressure is
greater than the maximum normal
operating pressure of the process fluid but
less than the maximum safe working
pressure of the equipment.
 When the fluid pressure exceeds the set
point pressure, the valve pops fully open.
This happens very quickly to release
overpressure as quickly as possible. The
pressure at which the valve closes again is
lower than the opening set point pressure.
The difference between opening and closing
pressures is called the blow down.

© 2014 / CONFIDENTIAL ISLAM DEIF 70

SPECIAL VALVES
Pressure safety valves
 Blow down is given as a percentage of opening setpoint pressure.
EXAMPLE a valve may open at 15bar with a blowdown of 10%.
10% of 15bar is 1.5bar
the valve will close at a pressure that is 1.5bar lower than 15bar
15bar – 1.5bar = 13.5bar.
 PSVs on gas processing systems normally vent to flare—the valve outlet
is connected to the flare system where the gas burns off.

 PSVs on steam systems vent to atmosphere—the steam is released into

the air.

© 2014 / CONFIDENTIAL ISLAM DEIF 71

SPECIAL VALVES
Needle Valves
 Needle valves are linear-motion valves. They can make very small
adjustments to flow rate. Their name comes from the long, tapered shape
of the bottom of the spindle that forms the closing element.

© 2014 / CONFIDENTIAL ISLAM DEIF 72

SPECIAL VALVES
Needle valve Positions

© 2014 / CONFIDENTIAL ISLAM DEIF 73

SPECIAL VALVES
Check Valves
 Non-return valves, also called check valves, stop flow reversal in a pipe.
They only allow fluid to flow in one direction.
 The pressure of the fluid passing through the valve in the correct
direction opens it automatically. If the flow tries to reverse, the valve
closes automatically.They have an arrow on the body that shows the
correct flow direction,. Make sure that you mount non-return valves the
correct way round.

© 2014 / CONFIDENTIAL ISLAM DEIF 74

SPECIAL VALVES
Swing Check valve
 In this type, the valve disc is hinged at the top. When there is no flow, the
weight of the disc closes the valve.

© 2014 / CONFIDENTIAL ISLAM DEIF 75

SPECIAL VALVES
Lift Check Valves
 These valves have a similar valve body and seating arrangement to globe
valves.
 Flow must enter from under the seat to lift the closing element. Flow in
the reverse direction pushes the closing element against its seat.

© 2014 / CONFIDENTIAL ISLAM DEIF 76

SPECIAL VALVES
Piston Check Valves
 Piston check valves are similar to lift check valves. Instead of a valve disc
there is a piston that slides in a cylinder. This gives a smoother motion
during operation.

© 2014 / CONFIDENTIAL ISLAM DEIF 77

SPECIAL VALVES
Ball Check Valves
 These have a spherical (ball-shaped) closing element. Like the other check
valves, the closing element may operate by gravity or the flow pressure or
it may be spring loaded.

© 2014 / CONFIDENTIAL ISLAM DEIF 78

CONTROL VALVE
BODY SELECTION

© 2014 / CONFIDENTIAL ISLAM DEIF 79

CONTROL VALVE BODY SELECTION

Globe (Plug and Seat)

 These are the most traditionally used control valves - generally available
from 12 to 400mm in all castable materials. Larger sizes are available but
it becomes more common to move to an angle construction on these
sizes.

 Pressure ratings up to ANSI 2500# and higher are available.

 The globe valve is very versatile offering reduced trim options as well as a
variety of special trims for severe high pressure drop applications.This
style of valve is easily adapted for use on cryogenic temperatures, and for
high temperature duties.

 Turndown capability of 50:1 is available.

© 2014 / CONFIDENTIAL ISLAM DEIF 80

CONTROL VALVE BODY SELECTION

Butterfly
 The least expensive of all control valves. Sizes range from 50 to 3000mm.

 Pressure ratings are generally up to 1600 kpa(G).

 Temperatures are up to 100C. This valve is good for corrosive

applications but does not handle high pressure drops well. It is the lightest
valve available - size for size. Turndown is 75:1.

© 2014 / CONFIDENTIAL ISLAM DEIF 81

CONTROL VALVE BODY SELECTION

Diaphragm / Pinch
 These valves are inexpensive and very simple in operation.They are used
extensively in the mining industry for control of slurries and water.
 The characteristic is basically quick opening and so these valves do not
give precise control or high turndown but function particularly well on
level control.Very good for low pressure abrasive applications.
 Sizes are available from 25 to 350mm in pressure ratings up to 1000kPa
on the smaller sizes and 350kPa above 200mm. Special pinch valves can
handle pressures up to 100 bar.
 Temperature limitation is about 100C. Turndown is 10:1.

© 2014 / CONFIDENTIAL ISLAM DEIF 82

CONTROL VALVE BODY SELECTION

Ball
 Ball valves naturally have a good control characteristic and give high
turndown of 100:1 for standard ball valves and up to 500:1 for vee ported
valves.
 High pressure valves are available to ANSI 2500# and higher - most valves
working at greater than 3000kPa have trunnion mounted balls.
 Sizes range from 10mm to 500mm.
 High temperatures are handled by valves with metal seats.
 Full ball valves are not recommended for slurries due to the solids
settling out in the body cavity.
 High pressure drops are not handled well due to the ball causing high
velocity jets of fluid directed into the seat and body - resulting in erosion.
 This design of valve is particularly suitable for use with ceramic materials
and can be used on abrasive throttling duties where the pressures and
temperatures are too high for pinch or diaphragm valves.

© 2014 / CONFIDENTIAL ISLAM DEIF 83

CONTROL VALVE BODY SELECTION

© 2014 / CONFIDENTIAL ISLAM DEIF 84

PACKING

© 2014 / CONFIDENTIAL ISLAM DEIF 85

CONTROL VALVE PACKING
WHAT IS 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 so no leaks occur between the moving stem and the
body of the valve. The general term for this sealing mechanism is packing.

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CONTROL VALVE PACKING
PACKING IN SLIDING STEM VALVE
 The packing material takes the
form of several concentric rings,
stacked on the valve stem like
washers on a bolt. These packing
rings are forced down from
above by the packing flange to
apply a compressive force
around the circumference of the
valve stem. This compressive
force is necessary to generate
mechanical stress in the packing
material to make it seal tightly
against the stem of the valve and
the interior wall of the bonnet.

© 2014 / CONFIDENTIAL ISLAM DEIF 87

CONTROL VALVE PACKING
STATIONARY LOADING
 The packing shown here is “loaded” by the compressive force exerted by
the packing follower.
 The only elasticity in this particular system resides in the packing material
itself. This is called stationary loading, otherwise known as jam packing.
 Over time, as the packing material wears and fatigues, the packing
follower must be re-compressed by carefully tightening the packing nuts.

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CONTROL VALVE PACKING
LIVE-LOADED VALVE STEM PACKING
 An alternative to “stationary” loading is to insert a metal spring into the
packing assembly, so that the elasticity of the spring helps to maintain an
appropriate amount of packing stress as the packing material wears and
ages. This is called live loading

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CONTROL VALVE PACKING
ADJUSTING PACKING ASSEMBLE

© 2014 / CONFIDENTIAL ISLAM DEIF 90

CONTROL VALVE PACKING
PACKING MATERIAL SELECTION
 The two most common packing materials in use today are Teflon (PTFE)
and graphite. Teflon is the better of the two with regard to fluid sealing,
stem friction, and stem wear. Teflon is also quite resistant to attack from a
wide variety of chemical substances.

 Unfortunately, it has a limited temperature range and cannot withstand

intense nuclear radiation. Graphite is another self-lubricating packing
material, and it has a far greater temperature range than Teflon as well as
the ability to withstand harsh nuclear radiation, but creates much more
stem friction than Teflon.

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CONTROL VALVE PACKING
PACKING MATERIAL SELECTION
 Graphite packing also has the unfortunate property of permitting galvanic
corrosion between the stem and bonnet metals due to its electrical
conductivity. Sacrificial zinc washers are sometimes added to graphic
packing assemblies to help mitigate this corrosion, but this only
postpones rather than prevents corrosive damage to the stem.

 Hybrid packing materials, such as carbon-reinforced Teflon, also exist in an

attempt to combine the best characteristics of both technologies.

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CONTROL VALVE PACKING
Typical Packing friction values

© 2014 / CONFIDENTIAL ISLAM DEIF 93

CONTROL VALVE PACKING
PACKING MATERIAL SPECIFICATION

Suitablity
Temp. for Oxygen Stem Special
Common use Packing material Description
Range /Oxidizing friction consideration
Service
Split rings of braided
PTFE impregented
-73 to 232C Non-Radioactive Yes composition impregented with Low -
composition
PTFE
All chemicals ( Except
Required 2 to 4
Molten alkali) Non No single PTFE V - Ring Solid rings of molded PTFE Low
micro inch RMS
-40 to 232C radioactive
valve plug stem
Vacuum Pressure /
No Double PTFE V - Ring Solid rings of molded PTFE Low finish
Vacuum
Split rings of braided,
preshrunk PTFE yarn
impregented with PTFE;
Vacuum, All chemicals available with copper rings at
-84 to 232C Yes Chesterton 324 Low -
( Except molten alkali ) top and bottom of packing
box to meet UOP
specification 6-14-0 for acid
service.
Low chloride
Water, Stem Petroleum Ribbon style graphite rings content ( less then
products, Radiactive Yes but upto Graphite/ and rings of braided graphite 100ppm) chrome
-18 to 538C High
and Non-radiactive 371C Ribbon/Filament fibers with sacrificial zinc plated stem not
nuclear washer necessary for high
temperature service
Solid rings of ribbon-style
High temperature Ribbon - Style
371 to 649C Yes graphite with sacrificial zinc High -
oxidizing service graphite
washers

© 2014 / CONFIDENTIAL ISLAM DEIF 94

SHUTOFF CLASSES

© 2014 / CONFIDENTIAL ISLAM DEIF 95

SHUTOFF CLASSES
VALVE SEAT LEAKAGE
 In some process applications, it is important that the control valve be able
to completely stop fluid flow when placed in the “closed” position.
 Many control valves spend most of their operating lives in a partially-open
state, rarely opening or closing fully. Additionally, some control valve
designs are notorious for the inability to completely shut off (e.g. double-
ported globe valves).
 Given the common installation of manual “block” valves upstream and
downstream of a control valve, there is usually a way to secure zero flow
through a pipe even if a control valve is incapable of tight shut-off. For
some applications, however, tight control valve shut-off is a mandatory
requirement.
 A control valve's ability to shut off has to do with many factors as the
type of valves for instance. A double seated control valve have very poor
shut off capability.The guiding, seat material, actuator thrust, pressure
drop, and the type of fluid can all play a part in how well a particular
control valve shuts off.

© 2014 / CONFIDENTIAL ISLAM DEIF 96

SHUTOFF CLASSES
VALVE LEAKAGE CLASSIFICATIONS
 Class I - Valve Leakage Classifications
Identical to Class II, III, and IV in construction and design intent, but no actual
shop test is made. Class I is also known as dust tight and can refer to
metal or resilient seated valves.

© 2014 / CONFIDENTIAL ISLAM DEIF 97

SHUTOFF CLASSES
VALVE LEAKAGE CLASSIFICATIONS
 Class II - Valve Leakage Classifications
Intended for double port or balanced singe port valves with a metal piston
ring seal and metal to metal seats.
0.5% leakage of full open valve capacity.
Service dP or 50 psid (3.4 bar differential), whichever is lower at 50 to 125 F.
Test medium air at 45 to 60 psig is the test fluid.

Typical constructions:
 Balanced, single port, single graphite piston ring, metal seat, low seat load
 Balanced, double port, metal seats, high seat load

© 2014 / CONFIDENTIAL ISLAM DEIF 98

SHUTOFF CLASSES
VALVE LEAKAGE CLASSIFICATIONS
 Class III - Valve Leakage Classifications
Intended for the same types of valves as in Class II.
0.1% leakage of full open valve capacity.
Service dP or 50 psid (3.4 bar differential), whichever is lower at 50 to 125 oF.
Test medium air at 45 to 60 psig is the test fluid.

Typical constructions:
 Balanced, double port, soft seats, low seat load
 Balanced, single port, single graphite piston ring, lapped metal seats,
medium seat load

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SHUTOFF CLASSES
VALVE LEAKAGE CLASSIFICATIONS
 Class IV - Valve Leakage Classifications
Intended for single port and balanced single port valves with extra tight piston
seals and metal to-metal seats.
0.01% leakage of full open valve capacity.
Service dP or 50 psid (3.4 bar differential), whichever is lower at 50 to 125 oF.
Test medium air at 45 to 60 psig is the test fluid.

Typical constructions:
 Balanced, single port, Teflon piston ring, lapped metal seats, medium seat
load
 Balanced, single port, multiple graphite piston rings, lapped metal seats
 Unbalanced, single port, lapped metal seats, medium seat load
 Class IV is also known as metal to metal

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SHUTOFF CLASSES
VALVE LEAKAGE CLASSIFICATIONS
 Class V - Valve Leakage Classifications
Intended for the same types of valves as Class IV.
The test fluid is water at 100 psig or operating pressure.
Leakage allowed is limited to 5 x 10 ml per minute per inch of orifice
diameter per psi differential.
Service dP at 50 to 125 oF.

Typical constructions:
 Unbalanced, single port, lapped metal seats, high seat load
 Balanced, single port, Teflon piston rings, soft seats, low seat load
 Unbalanced, single port, soft metal seats, high seat load

© 2014 / CONFIDENTIAL ISLAM DEIF 101

SHUTOFF CLASSES
VALVE LEAKAGE CLASSIFICATIONS
 Class VI - Valve Leakage Classifications
Class Vl is known as a soft seat classification. Soft Seat Valves are those
where the seat or shut-off disc or both are made from some kind of
resilient material such as Teflon. Intended for resilient seating valves.
The test fluid is air or nitrogen.
Pressure is the lesser of 50 psig or operating pressure.
The leakage limit depends on valve size and ranges from 0.15 to 6.75 ml
per minute for valve sizes 1 through 8 inches.

Typical constructions:
 Unbalanced, single port, soft seats, low load

© 2014 / CONFIDENTIAL ISLAM DEIF 102

SHUTOFF CLASSES
VALVE LEAKAGE CLASSIFICATIONS
 Class VI - Valve Leakage Classifications

Port Diameter Bubbles per ml per

inches Millimeters minute minute
1 25 1 0.15
1 1/2 38 2 0.30
2 51 3 0.45
2 1/2 64 4 0.60
3 76 6 0.90
4 102 11 1.70
6 152 27 4.00
8 203 45 6.75
10 254 63 9
12 305 81 11.5

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SHUTOFF CLASSES
VALVE LEAKAGE CLASSIFICATIONS
Class VI - Valve Leakage Classifications
 The “bubble test” used for Class VI
seat leakage is based on the leakage
rate of air or nitrogen gas past the
closed valve seat as measured by
counting the rate of gas bubbles
escaping a bubble tube submerged
under water.

 It is from this leakage test procedure that the term bubble-tight shut-of
originates.

© 2014 / CONFIDENTIAL ISLAM DEIF 104

SHUTOFF CLASSES
Control Valve Leakage Classification - Overview
Testing Procedures
Leakage Class Maximum Leakage
Test Medium Test Pressure Required for
Designation Allowable
Establishing Rating
I x x x No test required
45 - 60 psig or 45 - 60 psig or
Air or water at 50 -
0.5% of rated maximum operating maximum operating
II 125o F
capacity differential whichever differential whichever
(10 - 52oC)
is lower is lower
0.1% of rated
III As above As above As above
capacity
0.01% of rated
IV As above As above As above
capacity
Maximum service Maximum service
0.0005 ml per minute
pressure drop across pressure drop across
of water per inch of Water at 50 to125oF
V valve plug not to valve plug not to
port diameter per psi (10 to 52oC)
exceed ANSI body exceed ANSI body
differential
rating rating
Actuator should be
50 psig or max rated adjusted to operating
Not to exceed Air or nitrogen at 50
differential pressure conditions specified
VI amounts shown in to 125o F (10 to
across valve plug with full normal
the table above 52oC)
whichever is lower closing thrust applied
© 2014 / CONFIDENTIAL ISLAM DEIF to valve plug seat
105
CONTROL VALVE
ACTUATORS

© 2014 / CONFIDENTIAL ISLAM DEIF 106

CONTROL VALVE ACTUATORS
ACTUATORS

These are the main types of actuator:

Manual
Pneumatic
Electric motor
Hydraulic
Self-actuated

© 2014 / CONFIDENTIAL ISLAM DEIF 107

CONTROL VALVE ACTUATORS
PNEUMATIC ACTUATORS

They are basically of two types

1. Diaphragm actuator
2. Piston actuator

These actuators are designed so that with a specific change of air pressure,
the spindle will move sufficiently to move the valve through its complete
stroke from fully-closed to fully-open.

© 2014 / CONFIDENTIAL ISLAM DEIF 108

CONTROL VALVE ACTUATORS
DIAPHRAGM ACTUATORS
They have compressed air applied to a flexible membrane called the
diaphragm.
They are single acting i.e. air is supplied from single side of the diaphragm.

© 2014 / CONFIDENTIAL ISLAM DEIF 109

CONTROL VALVE ACTUATORS
WHAT IS THE FORCE REQUIRED TO
ACT ON THE DIAPHRAGM ?
The amount of force (F) in units of
pounds generated by any fluid
pressing against any surface is equal
to the fluid’s pressure (P) in units of
PSI multiplied by the surface area (A)
in units of square inches (F = PA). In
the case of a circular diaphragm, with
area equal to πr2, the complete
formula for force is F = Pπr2. For
example, a control valve diaphragm
14 inches in diameter (radius = 7
inches) with an applied air pressure
of 15 PSI generates a linear force of
2309 pounds.

© 2014 / CONFIDENTIAL ISLAM DEIF 110

CONTROL VALVE ACTUATORS
DIAPHRAGM ACTUATORS ASSEMBLY

© 2014 / CONFIDENTIAL ISLAM DEIF 111

CONTROL VALVE ACTUATORS
PISTON ACTUATORS
Pneumatic actuators may take the form of pistons rather than diaphragms.
They can withstand higher input pressures.
Can offer small cylinder volumes.
Can be Single Acting or Double Acting

© 2014 / CONFIDENTIAL ISLAM DEIF 112

CONTROL VALVE ACTUATORS
HOW CAN MORE PRESSURE ENHANCE FORCE GENERATED ?!
Piston actuators generally have longer stroke lengths than diaphragm
actuators, and are able to operate on much greater air pressures. Since
actuator force is a function of fluid pressure and actuator area (F = PA),
this means piston actuators are able to generate more force than
diaphragm actuators of the same diameter. A 14 inch diaphragm operating
at a maximum pressure of 35 PSI generates 5388 pounds of force, but the
same size piston operating at a maximum pressure of 150 PSI generates
23091 pounds of force.

© 2014 / CONFIDENTIAL ISLAM DEIF 113

CONTROL VALVE ACTUATORS
WHY PISTON ACTUATORS CAN BEAR MORE PRESSURE ?!
The greater pressure rating of a piston actuator comes from the fact that the
only “soft” component (the sealing ring) has far less surface area exposed
to the high pressure than a rolling diaphragm. This results in significantly
less stress on the elastic ring than there would be on an elastic diaphragm
exposed to the same pressure. There really is no limit to the stroke
length of a piston actuator as there is with the stroke length of a
diaphragm actuator. It is possible to build a piston actuator miles long, but
such a feat would be impossible for a diaphragm actuator, where the
diaphragm must stretch (or roll) the entire stroke length.

© 2014 / CONFIDENTIAL ISLAM DEIF 114

CONTROL VALVE ACTUATORS
DOUBLE ACTING PISTON

© 2014 / CONFIDENTIAL ISLAM DEIF 115

CONTROL VALVE ACTUATORS
Rotating Actuators (RACK-AND PINION
MECHANISM)
A pair of pneumatically-actuated pistons move a
rack and pinion mechanism to convert linear piston
motion into rotary shaft motion to move the
butterfly trim.

© 2014 / CONFIDENTIAL ISLAM DEIF 116

CONTROL VALVE ACTUATORS
HYDRAULIC ACTUATORS
Hydraulic actuators use liquid pressure rather than gas pressure to move the
valve mechanism. Nearly all hydraulic actuator designs use a piston rather
than a diaphragm to convert fluid pressure into mechanical force. The high
pressure rating of piston actuators lends itself well to typical hydraulic
system pressures, and the lubricating nature of hydraulic oil helps to
overcome the characteristic friction of piston-type actuators. Given the
high pressure ratings of most hydraulic pistons, it is possible to generate
tremendous actuating forces with a hydraulic actuator, even if the piston
area is modest.

© 2014 / CONFIDENTIAL ISLAM DEIF 117

CONTROL VALVE ACTUATORS
Examples

© 2014 / CONFIDENTIAL ISLAM DEIF 118

CONTROL VALVE ACTUATORS
TECHNICAL NOTES ABOUT HYDRAULIC ACTUATORS

They exhibit very stable positioning owing to the non-compressibility of

hydraulic oil. Unlike pneumatic actuators, where the actuating fluid (air) is
“elastic,” the oil inside a hydraulic actuator cylinder does not yield appreciably
under stress. If the passage of oil to and from a hydraulic cylinder is blocked
by small valves, the actuator will become firmly “locked” into place. This is an
important feature for certain valve-positioning applications where the actuator
must firmly hold the valve position in one position.

Some hydraulic actuators contain their own electrically-controlled pumps to

provide the fluid power, so the valve is actually controlled by an electric signal.
Other hydraulic actuators rely on a separate fluid power system (pump,
reservoir, cooler, hand or solenoid valves, etc.) to provide hydraulic pressure
on which to operate.

© 2014 / CONFIDENTIAL ISLAM DEIF 119

CONTROL VALVE ACTUATORS
Hydraulic pressure supply systems, however, tend to be more limited in
physical span than pneumatic distribution systems due to the need for thick-
walled tubing (to contain the high oil pressure), the need to purge the system
of all gas bubbles and the problem of maintaining a leak-free distribution
network.

Another disadvantage of hydraulic systems compared to pneumatic is lack of

intrinsic power storage. Compressed air systems, by virtue of air’s
compressibility (elasticity), naturally store energy in any pressurized volumes,
and so provide a certain degree of “reserve” power in the event that the main
compressor shut down. Hydraulic systems do not naturally exhibit this
desirable trait.

© 2014 / CONFIDENTIAL ISLAM DEIF 120

CONTROL VALVE ACTUATORS
PRACTICAL ASSEMBLY
A hydraulic piston actuator attached to a large shut-off valve (used for on/off
control rather than throttling).Two hydraulic cylinders may be seen above
the round valve body, mounted horizontally. Like the pneumatic piston
valve shown earlier, this valve actuator uses a rack-and-pinion mechanism
to convert the hydraulic pistons’ linear motion into rotary motion to turn
the valve trim

© 2014 / CONFIDENTIAL ISLAM DEIF 121

CONTROL VALVE ACTUATORS
Electric Actuators (MOV)
Electric operators with proportional or infinite positioning control have
limited use in the process industries. Their primary use has been in remote
areas, such as tank farms and pipeline stations, where no convenient air supply
is available. Slow operating speeds, maintenance problems in hazardous areas
and economics have prevented wide acceptance for throttling applications.

Electric motors have long been used to actuate large valves, especially valves
operated as on/off (“shutoff”) devices. Advances in motor design and motor
control circuitry have brought motor operated valve (MOV) technology to
the point where it now competes with legacy actuator technologies such as
pneumatic in actuating throttling valves as well.

© 2014 / CONFIDENTIAL ISLAM DEIF 122

CONTROL VALVE ACTUATORS
An electric actuator providing on/off
rotary actuation to a ball valve. This
particular electric actuator comes with a
hand crank for manual operation, in the
event that the electric motor (or the
power provided to it) fails

© 2014 / CONFIDENTIAL ISLAM DEIF 123

CONTROL VALVE ACTUATORS
Electric motors require no external fluid power system to function, unlike
pneumatic or hydraulic actuators. All they require is a source of electrical
power (often 480 volts AC, three-phase). Some electric valve actuators even
have the capability of operating from the power of an electric battery pack, for
reliable operation in the event of a power system outage.Virtually all electric
valve actuators require some form of feedback to indicate the valve’s position.

At minimum, this consists of limit switches to indicate when the valve is fully
shut and fully open. For throttling services, an electric actuator requires an
actual valve position sensor so that it may precisely adjust the valve to any
desired state. This sensor may take the form of a potentiometer, or a variable
differential transformer (LVDT or RVDT)

© 2014 / CONFIDENTIAL ISLAM DEIF 124

CONTROL VALVE ACTUATORS
Hand Actuators
The most common manual actuators are:
Hand wheel—for linear motion valves: gate valves, globe valves.
lever—for rotational motion valves: ball valves, butterfly valves.
It can be operate normally with all type of valves

© 2014 / CONFIDENTIAL ISLAM DEIF 125

CONTROL VALVE ACTUATORS
Some examples for manual actuator

© 2014 / CONFIDENTIAL ISLAM DEIF 126

CONTROL VALVE ACTUATORS
Self Actuated Valves
Although not a type of actuator itself, a form of actuation worthy of mention
is where the process fluid pressure itself actuates a valve mechanism. This
self-operating principle may be used in throttling applications or on/off
applications, in gas or liquid services alike. The process fluid may be
directly tubed to the actuating element (diaphragm or piston), or passed
through a small mechanism called a pilot to modulate that pressure
before reaching the valve actuator. This latter design allows the main
valve’s motion to be controlled by an adjustable device (the pilot).

© 2014 / CONFIDENTIAL ISLAM DEIF 127

CONTROL VALVE ACTUATORS
Self-operated, spring-loaded gas pressure regulating valve
A spring tries to force the plug off the seat, while “feedback” gas pressure
from the downstream side of the valve acts against a flexible diaphragm to
move the plug toward the seat.
The less downstream pressure, the more the trim opens up; the more
downstream pressure, the more the trim shuts off. This spring establishes the
pressure-regulating “setpoint” value for the regulator.

© 2014 / CONFIDENTIAL ISLAM DEIF 128

CONTROL VALVE ACTUATORS
Pilot-loaded or externally-loaded pressure regulator
Externally supplied loading pressure does that. Since this loading pressure is
easily adjusted by turning the knob on the manual-set pressure regulator,
the main regulator now becomes adjustable as well. The pilot mechanism
controls the main gas throttling mechanism, hence the name pilot.

© 2014 / CONFIDENTIAL ISLAM DEIF 129

CONTROL VALVE ACTUATORS
Actuator types symbols

© 2014 / CONFIDENTIAL ISLAM DEIF 130

VALVE FAILURE
MODES

© 2014 / CONFIDENTIAL ISLAM DEIF 131

VALVE FAILURE MODES
What is the meaning Failure ?!
By failure we mean the loss of the source of the actuating power supplied to
the valve body .

For electrically actuated valves, this is typically the last position the valve was
in before loss of electric power.

For pneumatic and hydraulic actuated valves, the option exists of having a large
spring provide a known “fail-safe” position (either open or closed) in the
event of fluid pressure (pneumatic air pressure or hydraulic oil pressure) loss.

© 2014 / CONFIDENTIAL ISLAM DEIF 132

VALVE FAILURE MODES
Direct/Reverse actions
The fail-safe mode of a pneumatic/spring valve is a function of both the
actuator’s action and the valve body’s action.

For sliding-stem valves

1st Actuator :
A direct-acting actuator pushes down on the stem with increasing pressure
while a reverse-acting actuator pulls up on the stem with increasing pressure.

2nd Valve Body

Sliding-stem valve bodies are classified as direct-acting if they open up when
the stem is lifted, and classified as reverse-acting if they shut off (close) when
the stem is lifted.

© 2014 / CONFIDENTIAL ISLAM DEIF 133

VALVE FAILURE MODES
Direct Body

© 2014 / CONFIDENTIAL ISLAM DEIF 134

VALVE FAILURE MODES
Reverse Body

© 2014 / CONFIDENTIAL ISLAM DEIF 135

VALVE FAILURE MODES
Failure modes Symbols
Valve fail mode may be shown in instrument diagrams by either an arrow
pointing in the direction of failure (assuming a direct-acting valve body
where stem motion toward the body closes and stem motion away from
the body opens the valve trim) and/or the abbreviations “FC” (fail closed)
and “FO” (fail open).

© 2014 / CONFIDENTIAL ISLAM DEIF 136

VALVE FAILURE MODES
How to select failure mode for a control valve
In fact, this basic principle forms the basis of decisions made for all instrument
actions in critical control loops: first determine the safest mode of valve
failure, then select and/or configure instrument actions in such a way that
the most probable modes of signal path failure will result in the control
valve consistently moving to that (safest) position.

Practical Example

© 2014 / CONFIDENTIAL ISLAM DEIF 137

ACTUATOR
BENCH-SET

© 2014 / CONFIDENTIAL ISLAM DEIF 138

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

Where,
F = Force applied to spring in newtons (metric) or pounds (British)
k = Constant of elasticity, or “spring constant” in newtons per meter (metric)
or pounds perfoot (British)
x = Displacement of spring in meters (metric) or feet (British)

© 2014 / CONFIDENTIAL ISLAM DEIF 139

ACTUATOR BENCH-SET
Hooke’s Law is a linear function, which means that spring motion will be
linearly related to applied force from the actuator element (piston or
diaphragm). Since the working area of a piston or diaphragm is constant, the
relationship between actuating fluid pressure and force will be a simple
proportion (F = PA). By algebraic substitution, we may alter Hooke’s Law to
include pressure and area:

F = kx
PA = kx

© 2014 / CONFIDENTIAL ISLAM DEIF 140

ACTUATOR BENCH-SET
Bench-Set Adjust

© 2014 / CONFIDENTIAL ISLAM DEIF 141

ACTUATOR BENCH-SET
Bench-Set Adjust
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.

© 2014 / CONFIDENTIAL ISLAM DEIF 142

ACTUATOR BENCH-SET
Case 1

© 2014 / CONFIDENTIAL ISLAM DEIF 143

ACTUATOR BENCH-SET
Case 2

© 2014 / CONFIDENTIAL ISLAM DEIF 144

ACTUATOR BENCH-SET
Summary
Once the stem length has been properly set by adjusting the stem connector,
the spring adjuster must be 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.

Bench set is a very important parameter for a control valve because it

establishes the seating force of the plug against the seat when the valve is fully
closed. Proper seating pressure is critical for tight shut-off, which carries safety
implications in some process services.

© 2014 / CONFIDENTIAL ISLAM DEIF 145

ACTUATOR
RESPONSE

© 2014 / CONFIDENTIAL ISLAM DEIF 146

ACTUATOR RESPONSE
Actuator response problem
A limitation inherent to pneumatic valve actuators is the amount of air flow
required to or from the actuator to cause rapid valve motion.This is an
especially acute problem in all-pneumatic control systems, where the distance
separating a control valve from the controller may be large.
This was serious problem in pneumatic control systems .

© 2014 / CONFIDENTIAL ISLAM DEIF 147

ACTUATOR RESPONSE
1st Using I/P transducer
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
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.

© 2014 / CONFIDENTIAL ISLAM DEIF 148

ACTUATOR RESPONSE
I/P transducer
A “current to pressure” transducer (I/P) converts an analog signal (4 to 20
mA) to a proportional linear pneumatic output (3 to 15 psig). Its purpose is to
translate the analog output from a control system into a precise, repeatable
pressure value to control pneumatic actuators.
The I/P converter uses an electromagnetic force balance principle to change
electrical signals into pneumatic signals. Typically, a 4 – 20mA input is
converted into a 3 – 15pisg output.

© 2014 / CONFIDENTIAL ISLAM DEIF 149

ACTUATOR RESPONSE
2nd Using Volume booster
One way to improve valve response in either type of system is to use a device
known as a volume booster 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 but with greatly enhanced flow capacity.

© 2014 / CONFIDENTIAL ISLAM DEIF 150

ACTUATOR RESPONSE
Volume booster VS Pressure regulator
In either mechanism, an internal diaphragm senses output pressure and acts
against a restraining force to position an air flow throttling/venting
mechanism.

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CONTROL VALVE
POSITIONER

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CONTROL VALVE POSITIONER
Why do we need a positioner ?
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.

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CONTROL VALVE POSITIONER
Positioner is a control system ?!!!!
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.

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CONTROL VALVE POSITIONER
Advantages of adding positioner

Accurate positioning of the valve stem

Ability to change the valve characteristics
Increase the speed of response (acting like volume booster )
Reverse the action of a valve
Tight shutoff (improve valve seating )

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CONTROL VALVE POSITIONER
How can Positioner increase valve seating

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CONTROL VALVE POSITIONER
Electronic positioners
Electronic valve positioners, such as the Fisher model DVC6000, use an
electronic sensor to detect valve stem position, microprocessor to compare
that sensed stem position against the control
signal by mathematical subtraction (error = position − signal), then a
pneumatic signal converter and relay(s) to send air pressure to the valve
actuator.

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CONTROL VALVE POSITIONER
Examples for electronic positioner

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CONTROL VALVE POSITIONER
Examples for Pneumatic positioner

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SOLENOID VALVES
Solenoid Valve
A very common form of on/off valve used for pneumatic and hydraulic
systems alike is the solenoid valve.
A “solenoid” is nothing more than a coil of wire designed to produce a
magnetic field when energized. Solenoid actuators work by attracting a
movable iron armature into the center of the solenoid coil when energized,
the force of this attraction working to actuate a small valve mechanism.
Solenoid-actuated valves are usually classified according to the number of
ports (“ways”). A simple on/off solenoid valve controlling flow into one port
and out of another port is called a 2-way valve. Another style of solenoid
valve, where flow is directed in one path or to another path – much like a
single-pole double-throw (SPDT) electrical switch – is called a 3-way valve
because it has three fluid ports.

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SOLENOID VALVES
2-way solenoid valve
2-way solenoid valves operate in a manner analogous to single-pole single-
throw (SPST) electrical switches: with only one path for flow.

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SOLENOID VALVES
3-way solenoid valves
3-way solenoid valves operate in a manner analogous to single-pole double-
throw (SPDT) electrical switches: with two paths for flow sharing one
common terminal.

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SOLENOID VALVES
4-way solenoid valves
When a pneumatic actuator requires air pressure applied to two different
ports in order to move two different directions (such as the case for cylinders
lacking a return spring), the solenoid valve supplying air to that actuator must
have four ports: one for air supply (P), one for exhaust (E), and two for the
cylinder ports (typically labeled A and B).
the solenoid valve forces the piston-actuated valve stem to move down (shut
off) when the solenoid is de-energized. When the solenoid is energized, air is
directed to the bottom of the piston (with the top of the piston becoming
vented to atmosphere), causing the piston-actuated valve stem to move up
(open wide).

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SOLENOID VALVES
Summary

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PROXIMITY SWITCH
Proximity (limit) switch
A proximity switch is one detecting the proximity (closeness) of some object.
By definition, these switches are non-contact sensors, using magnetic, electric,
or optical means to sense the proximity of objects.
Inductive proximity switches sense the presence of metallic objects through
the use of a high-frequency magnetic field. Capacitive proximity switches sense
the presence of non-metallic objects through the use of a high-frequency
electric field. Optical proximity switches detect the interruption of a light
beam by an object. Ultrasonic proximity switches sense the presence of dense
matter by the reflection of sound waves.

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PROXIMITY SWITCH
Proximity (limit) switch

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PROXIMITY SWITCH
Quick Exhaust valve
It is used in case of quick venting is important in a control valve .

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SPLIT RANGE CONTROL
Basic Control Strategies
Open loop control
Single feedback control
Cascade control
Ratio control
Split range control

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SPLIT RANGE CONTROL
Split range Control
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. Split-ranged control valves may take
different forms of sequencing.
A few different modes of control valve sequencing are commonly seen in
industry:
Complementary
Exclusive
Progressive

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SPLIT RANGE CONTROL
Complementary valve sequencing
A mode where two valves serve to proportion a mixture of two fluid streams.

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SPLIT RANGE CONTROL
Exclusive valve sequencing
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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SPLIT RANGE CONTROL
Progressive valve sequencing
This mode used to expand the operating range of flow control for some fluid
beyond that which a single control valve could muster.