Introduction to Control valves

Classification of
Valves

2 Introduction to Control Valves

 Linear Motion Valves

Types of valves with a closure member that moves in linear

motion to modify the rate of flow through the valve

GLOBE VALVE: A valve with a linear motion closure member,

Globe Valve one or more ports and a body distinguished by a globular
shaped cavity around the port region.

GATE VALVE : A flat or wedge shaped (Gate) linear closure

member which may be moved in or out of the stream. It has a
straight-through flow path.

3 Introduction to Control Valves

Gate Valve
 Linear Motion Valves

DIAPHRAGM VALVE : A flexible linear motion closure member

that is forced into the internal flow passageway of the body by
the actuator.
Diaphragm Valve

PINCH OR CLAMP VALVE : A flexible elastomeric tubular

member connected to two rigid flow path ends whereby
modulation and/or shutoff of flow is accomplished by squeezing
the flexible member into eventual tight sealing contact.

4 Introduction to Control Valves

Pinch or Clamp Valve
 Rotary Motion Valves

Types of valves with a closure member that moves with a

rotary motion to modify the rate of flow through the valve

BALL VALVE: A valve which modifies flow rates with rotary

Ball Valve motion of the closure member which is either a sphere with an
internal passage or a segment of a spherical surface.

BUTTERFLY VALVE : Valve with circular body and a rotary

motion disk closure member, pivotally supported by its stem.

Butterfly Valve 5 Introduction to Control Valves

 Rotary Motion Valves

PLUG VALVE : with closure member that may be cylindrical,

conical or a spherical segment in shape. It is positioned, open to
closed, with rotary motion.

Plug Valve

6 Introduction to Control Valves

 Other main types

Check Valve: A check valve is a non-return valve, which

normally allows fluid to flow through it in only one direction. It
has no actuator part to control the opening.

Check Valve

Self Regulating valve: uses the output feedback signal valve

(pressure, pressure, temperature) to pass through the signal
tube to the valve actuator drive change in the valve opening, to
adjust the pressure, flow, temperature

7 Introduction to Control Valves

Self Regulating Valve
Typical Comparison of different types of valves w.r.t Globe Control valve

Pressure
Price Weight Cv Pressure Drop
Recovery

PLUG Similar More High Less More

DIAPHRAGM Medium Medium High Medium Medium

PINCH Medium Medium High Less Medium

GATE Less Less High Less More

BALL Less Less High Less More

BUTTERFLY Less Less High Less More

8 Introduction to Control Valves

Typical Comparison of different types of valves w.r.t Globe Control valve

Pressure Pressure Slurry Class

Price Weight Cv
Drop Recovery Service Leakage

PLUG Similar More High Less More Not Suitable Average

DIAPHRAGM Medium Medium High Medium Medium Suitable High

PINCH Medium Medium High Less Medium Suitable Less

Well
GATE Less Less High Less More High
Sustainable

BALL Less Less High Less More Not Suitable Less

BUTTERFLY Less Less High Less More Not Suitable Less

9 Introduction to Control Valves

Basic Terms
Control System

A control system is a device or set of devices to control, actuate, direct or regulate the
behavior of other devices or systems. It includes following components in general
ƒ sensing element
ƒ controller
ƒ final control element (control valve)

10 Introduction to Control Valves

 Basic Terms
Control System

11 Introduction to Control Valves

Basic Terms
Control System

12 Introduction to Control Valves

Basic Terms
Valve

Valve: A valve is a device used for the control of fluid flow. It consists of a fluid retaining
assembly, one or more ports between end openings and a movable closure member, which
opens, restricts or closes the port(s)

Actuator: An actuator is a fluid powered or electrically powered device, which supplies force
and motion to a valve closure member.

Control Valve: A power operated device, which modifies the fluid flow rate in a process
control system. It consists of a valve connected to an actuator mechanism that is capable of
changing the position of a flow controlling element in the valve in response to a signal from the
controlling system.

13 Introduction to Control Valves

MIL Product Range
Globe Control Valve

Mechanical Anatomy

14 Introduction to Control Valves

 Basic Terms
Body / Bonnet
Bonnet
Body: The part of the valve which is
the main pressure boundary. The body
also provides the pipe connecting
Body
ends, the fluid flow passageway, and
may support the seating surfaces and
Guide the valve closure member.

Bonnet: That portion of the valve

pressure retaining boundary which
may guide the stem and contains the
packing box and stem seal. It may also
provide the principal opening to the
body cavity for assembly of internal
parts or be an integral part of the valve
Plug body. It may also provide for the
attachment of the actuator to the valve
Seat
body.

15 Introduction to Control Valves

 Body Types

Inline Y - type
Z - type

Angle Type 3 – Way Type

16 Introduction to Control Valves

Types of Bonnet Seal
Typical bonnets are bolted, threaded, or welded to or integral
with the body.

Bolted: Bonnet is bolted to the body using stud and nut enabling
the easy removal of the bonnet for trim maintenance etc.

Integral : Bonnet will be an integral part of the body. Mainly for

smaller size valves.

Seal welded bonnet: A bonnet welded to a body, at assembly,

to provide a zero leakage joint. This construction consists of a
low-strength weld with the bonnet retained to the body by other
means to withstand the body pressure load acting on the bonnet
area.
17 Introduction to Control Valves
Bonnet Types
Special

Extension bonnet
A bonnet with a packing box that is extended above the bonnet
joint of the valve body so as to maintain the temperature of the
packing above or below the temperature of the 'process fluid.
The length of the extension bonnet is dependent upon the
difference between the fluid temperature and the packing design
temperature limit as well as upon the valve body design

18 Introduction to Control Valves

 Stem Sealing Arrangements
Stem seals: The part or parts needed to effect a pressure tight seal
Packing Stud
around the stem while allowing movement of the stem.
and Nut
Packing Main Parts
Flange

Packing
Follower Packing Box: The chamber, in the bonnet, surrounding the stem and
containing packing and other stem sealing parts.
Packing
Rings
Packing follower: A part which transfers mechanical load to the
Packing packing from the packing flange or nut.
Spacer

Packing: A sealing system consisting of deformable material of one or

more mating and deformable elements contained in a packing box
which may have an adjustable compression means to obtain or
maintain an effective pressure seal.

Lantern ring: A rigid spacer assembled In the packing box with

Typical Packing packing normally above and below it and designed to allow lubrication
of the packing or access to a leak-off connection.
19 Introduction to Control Valves
Stem Sealing Arrangements
Types of Stem Sealing

Pressure energized stem seal: A part and/or packing material deformable

by fluid pressure that bears against the stem to make a tight seal.

Ecolock Packing : Special packing set / cartridge designed with packing

rings of varying density so that it ensures even and uniform compression.
This would ensure that the radial force exerted on the stem is also uniform
thus resulting in reduced friction in the packing box and smooth operation
even in high pressure applications

Bellows stem seal: A thin wall, convoluted, flexible member which makes
a seal between the stem and bonnet or body and allows stem motion while
maintaining a positive seal.

Packing Materials:
PTFE: Up to < 183oC
Graphite:> 183oC

20 Introduction to Control Valves

Different Guiding Mechanisms
Top Guiding
Globe valve plug guides: The
means by which the plug is aligned
with the seat and held stable
throughout its travel. The guide Is
held rigidly in the body or bonnet.

Stem guide: A guide bushing

closely fitted to the valve stem and
aligned with the seat.

Disadvantage: Higher pressure

drops and minor cavitation can
excite vibrational modes that are
very destructive and can result in
valve failure.

21 Introduction to Control Valves

Different Guiding Mechanisms
Top Guiding
Post guide: Guide bushing or
bushings fitted to posts or
extensions larger than the valve
stem and aligned with the seat.

Advantage: Provides rigid guiding

and ensures stable operation even
in high pressure service. Also
eliminates the need for a larger
stem by allowing large guide
surface.

22 Introduction to Control Valves

Different Guiding Mechanisms
Cage Guiding
Cage guide: A valve plug fitted to
the inside diameter of the cage to
align the plug with the seat.

Plug is guided throughout its travel

and eliminates vibrations due to
lateral thrust on the plug and
hence suited for higher pressure
drop application.

Quick-Change Trim & Easy

Maintenance

Cage guided trim shall be

Balanced or Unbalanced

23 Introduction to Control Valves

Balanced to Unbalanced trim
Un-Balanced trim: Combines advantages of superior cage guiding
and single seated leak tightness.
Balanced trim: An arrangement of ports and plug or combination of
plug, cage, seals and ports that tends to equalize the pressure above
and below the valve plug to minimize the net static and dynamic fluid
flow forces acting along the axis of the stem of a globe valve.

Smaller
Actuator
Lesser thrust
(Stem Force)`

Balanced
trim

Addition of
parts

High cost
24 Introduction to Control Valves
/Maintenance
Top & Bottom Guide

Top & Bottom Guiding / Port Guiding

Top & Bottom guide: Eliminates the possibility of cantilever
geometry of the top guided plug with its top & bottom
guiding. Also it incorporates simplest form of balanced
construction, thereby eliminating need for oversized
actuators in large size application. These valves are also
relatively insensitive to dirt with its large flow passages.

Port guide: A valve plug with wings or a skirt fitted to the

seat ring bore. This also is an economical and effective
method for restraint of the plug.

Port Guide

25 Introduction to Control Valves

Trims

Trim: The internal parts of a valve which are in flowing contact

with the controlled fluid, Except body, bonnet, bottom flange,
guide bush and soft parts (Packing, gaskets etc) . Examples are
the plug, seat ring, cage, stem and the parts used to attach the
stem to the plug.

Plug: A cylindrical closure member which moves In the flow

stream with linear motion to modify the flow rate and which may
or may not have a contoured portion to provide flow
characterization.

26 Introduction to Control Valves

Trims

Seat ring: A part that is assembled in the valve body and may
provide part of the flow control orifice. Seat Ring also can be an
integral part of the body or cage material or may be constructed
from material added to the body or cage.

Cage: A part in a globe valve surrounding the closure member to

provide alignment and facilitate assembly of other parts of the
valve trim. The cage may or may not also provide flow
characterization for globe valves.

27 Introduction to Control Valves

Basic Terms
Actuators

28 Introduction to Control Valves

 Actuators
Pneumatic Spring
Diaphragm Actuators
Actuator consists of complete
assembly of parts required to
operate a specific valve. Pneumatic
actuators converts the energy of a
compressible fluid, usually air into
motion. In Diaphragm actuators, the
fluid acts upon the flexible member
(diaphragm) to provide linear
motion to the actuator stem.
Air to Open
Air to Close
(Reverse) Act
(Direct) Act

29 Introduction to Control Valves

 Basic Terms
Valve Assembly

30 Introduction to Control Valves

Basic Terms in Construction

VALVE SIZE : Valve size is the size for which the valve flange or valve weld end is prepared to
connect the same to the pipe line.

BODY RATING : For proper working of the valve, the valve body shall be designed to work at
the maximum temperature and pressure.

Body rating is selected in accordance with ASME B16.34 rating chart..

Since most materials have a reduction in allowable working stress at elevated temperatures, the
pressure temperature rating must be considered in the choice of materials

31 Introduction to Control Valves

 Max. Allowed
Working Pressure as
per ASME 16.34

32 Introduction to Control Valves

Basic Terms in Construction

END CONNECTION : The end connections are the configurations provided to make a pressure
tight joint to the pipe carrying the fluid to be controlled. End connection on valves must match
piping design and specification.
In addition to the piping specification, other factors to be considered are

– Piping force that will act on the valve body

– Forces generated in the piping by valve action

There are different types of end connection based on different factors like temperature,
pressure, valve size etc.

33 Introduction to Control Valves

Types of End connections
Threaded

Normally female national pipe

taper (NPT) that conforms to
ASME standards. Tapered
thread forms a metal-to-metal
seal by wedging the tapered
threads together. Usually
limited to valves not larger than
2 inches.

34 Introduction to Control Valves

Types of End connections
Flanged
Flanged end connection are
tightened by a number of bolts
which individually require less
tightening than an individual
threaded joint for a given
application.
The use of flanged valves is
particularly convenient for
quickly removing a defective
valve from a line without a
protracted shut-down of
service.
Types of flanged joints

35 Introduction to Control Valves

Types of End connections
Welded
Welded end valves are used for installation in a pipe line to
eliminate all possibility of leakage.
Specifically for high pressure and high temperature applications
as well as for toxic, flammable and explosive fluid service
where no leakage to the environment can be tolerated.

Socket Welded
standardized in ASME B16.34 for valve sizes up to 2 inches.

Butt Welded
are common in high temperature ,high-pressure applications, as
in power generating plants for steam and feed water services

36 Introduction to Control Valves

Seat Leakage
Control valve users specify leakage based on an International standard ANSI/FCI 70.2.

The Leakage Class specified is as follows:

ƒ Class I - Understanding between supplier and purchaser.

ƒ Class II - 0.5% of rated valve flow coefficient

ƒ Class III - 0.1% of rated valve flow coefficient

ƒ Class IV - 0.01% of rated valve flow coefficient

ƒ Class V - 5 x 10-4 ml/min. of water/ psi of shut off pressure / inch of orifice dia.

ƒ Class VI - Bubble tight leak (measured as number of bubbles)

37 Introduction to Control Valves

Leakage Class Test Fluid Test Pressure Max. Leak Rate

Class II Water/ Air 3.5 bar 0.5% Of Cv

Class III Water/ Air 3.5 bar 0.1% of Cv

Class IV Water/ Air 3.5 bar 0.01% of Cv Seat Leakage

5x10-4 ml /min /
inch of orifice dia /
Class V Water Service Pressure
psi pressure drop

Air Depends On
Class VI 3.5 bar
Orifice Size

38 Introduction to Control Valves

39 Introduction to Control Valves