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 Shut Off Valve

Manual

Control Valve Selection

Categories
Guide
by Editorial Staff Select Category

Control valves play a major role in the everyday

effort to increase process plant profitability and
conserve energy.

Proper selection of these valves can have a

significant financial impact on the overall cost of a

project and how well the process can be controlled.

···

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 Table of Contents
Recent
Comments

Editorial Staff
on Basics of
1. Control Valve Selection Guide
Pressure
2. Controlling the valve
switches
3. Design parameters

4. Flow coefficient Majid Borairi

5. Trim and bonnet on Basics of

6. Bonnet Pressure

7. Noise switches

8. Selecting the type of valve Robert

9. Flow characteristic selection Sheridan on
10. Equal percentage Why 4 wire
11. Quick-opening RTD
12. Materials of construction Measurement
13. Maintenance Accuracy is
better than 2
Control Valve Selection Guide and 3 wire

To narrow down the choices, the engineer must RTD?

understand how the general characteristics of each Sanjeev

type of valve match up with the design requirements Deshpande
of the valves. on Open Loop
and Closed
Controlling the valve Loop

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 A control loop consists of a sensing element, a Animation
controller and the final control element — the valve Thomas Ben
and its actuator. The sensing element transmits a Abraham on
signal to a single controller or a distributed control What is OPC ?
system (DCS).
faruque on

The controller compares the signal with the setpoint, Recognizing

and then makes any needed corrections by sending an Over-

a signal to the control valve. The correction is Tuned PID

measured and verified by the sensing element, Controller by

completing the loop. Phase Shift

hauwa haruna

··· on 100 VHDL

Projects for
Engineering
In below Figure, the I/P transducer changes an
Students
electronic signal into one that is pneumatic. A control
valve should react instantaneously to any change in
the signal.

To be effective, a valve should:

operate
over a
wide

range
of flows
(have a wide rangeability);

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 accurately respond to any signal across its
operating range;
exhibit little dead time or hysteresis;
react to incremental adjustments from the
controller (resolution); and
respond with the required speed (stroking
speed).
A fast response may not be suitable for all
applications.

For example, a quick or sudden reduction in the

bore of a valve in a pipeline may be harmful, causing
a shock wave. A valve’s ability to control flow
depends upon the quality of its actuator.

A positioner may be added to obtain tighter control. More Articles

Positioners improve performance by amplifying the
1. What is an Altitude
controller’s signal, thereby achieving a more-precise
Valve?
response. This also helps to overcome the effects of
any valve-stem friction and improve shut-off. 2. Four Way Solenoid
Valve Working
Principle

3. Basics of Butterfly
Valves

4. Control Valves

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 Theory

5. Types of Failures

in Control Valves
··· 6. Control Valve
Interview Questions
and Answers

The quality of any control device can be quantified in 7. Valve Handwheel

terms of its gain, time constant and dead-time lag. Types : Fixed,

Of these, the gain is the most important for a control Hammer, Gear

valve. Gain is the ratio of the percentage change in a 8. How to

process variable to the percentage change of the Troubleshoot Control
valve travel. Gain depends upon the valve Valve? – Problems
characteristics and process conditions. and Solutions

Design parameters 9. Basics of Gate

Valves
To properly select a control valve, the following fluid

and system properties must be known: its state 10. Calculate Control

(vapor, liquid or two-phase), vapor pressure, Valve Stem Position

flowrate, inlet and outlet pressures, inlet

temperature, density, molecular weight, viscosity,
specific heat ratio, critical temperature and critical
pressure.

The maximum flowrate that is specified should

include an appropriate design margin (typically,

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 10%). Specification calls for knowing the system’s
geometry, size and pipe schedule number, and
materials of construction, as well as the valve’s fail-
safe position, maximum shut-off pressure and the
percent flash (for flashing fluids) through the valve.

Since a control valve is power-operated, the

engineer must consider its response to loss of signal
or power — i.e., the valve’s fail-safe mode. In about
80% of applications, control valves are specified to
fail closed. However, sometimes, the valve should
either fail open, lock (fail-in lock position) or drift
(slowly, to either close or open).

···

A fail-open valve would be needed in a deluge

system, for instance. Springs within the bonnet

normally enable the actuator to reach the failure
position. In some cases, such as for a lock position or
a fail drift, an auxiliary power source (e.g., an air
cylinder) may be required. Safety codes and

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 concerns, and process requirements will determine
the failure position.

Flow coefficient
The most important valve parameter for calculating
the size of a control valve is the flow coefficient,
Cv.Calculation of Cv depends upon whether the flow
is incompressible, compressible or mixed-phase.

There are equations for determining Cv for

incompressible, compressible, two-phase, and
cavitating or flashing fluids. These references allow a
preliminary valve size to be computed.

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 ···

Trim and bonnet

Trim : refers to the removable, internal parts of the
valve that are in contact with the flowing fluid. Parts
not considered as trim include the packing, bonnet,
bottom flange and gaskets. The trim maintains the
relationship between the flow capacity and valve-
plug lift, and ensures proper shut-off of the valve.

The seat is primarily responsible for the tightness of

shut-off. Correct lift and tight shut-off are also
affected by other parts of the valve, such as body
shape, actuator design and valve-stem packing. The
required level of tightness of shut-off depends upon
the type of service. Shut-off is measured by the
percentage of total flow that leaks through when the
valve is closed. There are industry standards that
define the shut-off requirements for various

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 applications.

A common standard that defines leakage classes is

“Control Valve Seat Leakage,” ANSI/FCI 70-2-1998
(3). The classes range from a weak shut-off (Class II)
to nearly zero leakage (Class VI). (Class I does not
have any standards or leak rate associated with it.)
Depending on the requirements, the user then sets
the tight shut-off (TSO) requirement as one of the
shut-off classes (normally IV, V or VI).

Valve trim selection is primarily based on the fluid

operating conditions, the manufacturer’s inherent
flow characteristic for a particular trim, and the
effect on the inherent flow characteristic at different
operating conditions. These parameters enable
prediction of the installed flow characteristic for
each trim, which is used as a basis for trim selection.

···

Reduced-capacity trim helps to attain precise

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 control at low flows, while leaving room for higher
flows in the future. Such trim is designed so that flow
through the port is lessened, but the precision of the
flow control is increased because of a reduced plug-
lift distance.

There is no general rule that states reduced trim

should be used below a certain turndown rate.
However, reduced trim may be a solution when
precise control is required at 20–25% of valve
capacity.

Cages are common in trim and serve

multiple purposes:

A cage serves as a guide for the plug,

ensuring that it is properly positioned and
makes the right contact with the seat.
A characterized cage can be used to alter the
installed flow characteristics of the valve. The
shape of the orifices cut into the cage
determine whether a valve is equal-
percentage, linear or quick-acting.
The cage can be designed to ensure a
balanced spread of liquid forces on the plug
and stem, resulting in what is known as a
cage-guided, balanced trim.

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 The plug and stem in a sliding-stem valve experience
forces that affect the actuator‘s control of the plug,
and result in jerky, inaccurate stem motions and high
dead-bands.

The fluid around the stem can push it up, down or

sideways, and even impart torsional forces on it.
There are trim designs that counteract and balance
these forces. A balanced trim uses mechanical
modifications to the plug or a cage trim to spread
and even out the forces.

···

Bonnet :
Special consideration must also be given to the
bonnet, which encases the actuator and the valve
packing. Bonnets are often designed to meet certain
temperature ranges.

For high (e.g., 450°F) and below freezing

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 temperature service, an extension bonnet is used.
This bonnet isolates the packing from extreme
temperatures.

In cryogenic service, the extension separates the

valve-stem packing from the sub-zero fluid,
preventing the packing from becoming brittle. An
externally finned bonnet is sometimes used for high
temperatures. The fins promote heat loss to the
ambient air.

Noise :

Control valves generate noise due to mechanical

vibrations, cavitation or aerodynamic effects. High
velocities, pressure oscillations and unsteady flow
create vibrations that are usually under 100 decibel
(dB), the intensity of sound at maximum level from
the earphones of a portable radio. (Normal
conversation is about 60 dB, and the eardrum’s pain
threshold is around 130 dB.)

···
The noise generated by cavitation depends upon its

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 degree. Increasing the pressure drop across a valve
will increase the noise. During full cavitation, a
control valve makes a rattling noise.

However, the noise is usually under 100 db.

Aerodynamic-generated noise results from the
mixing of turbulent fluids with laminar ones. This is
the most common and worst source of noise — levels
can reach over 100 db. The noise limitations for the
process need to be specified to the valve supplier

Selecting the type of valve

Valve manufacturers will provide actual valve flow
capacity, expressed in terms of Cv, for their various
valve sizes and types. Once a valve type and flow
characteristic are established, a preliminary size can
be determined by computing the valve stroke for
each design flow case.

The stroke is the ratio of the calculated Cv to the

actual Cv for a particular valve. Choose a valve that
can operate between 10–80% of the valve stroke
across the expected range of operation, i.e., the
minimum, normal and maximum flowrates.

Rules of thumb for sizing and selection

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 The following should be used as a guidelines, but not
as design criteria :

···

In a pumped circuit, the pressure drop

allocated to the control valve should be equal
to 33% of the dynamic losses in the system at
the rated flow, or 15 psi, whichever is greater.
The pressure drop allocated to a control valve
in the suction or discharge line of a centrifugal
compressor should be 5% of the absolute
suction pressure, or 50% of the dynamic
losses of the system, whichever is greater.
In a system where static pressure moves
liquid from one pressure vessel to another, the
pressure drop allocated to the valve should be
10% of the lower-terminal vessel pressure, or
50% of the system’s dynamic losses,
whichever is greater.
Pressure drops in valves in steam lines to

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 turbines, reboilers and process vessels should
be 10% of the design absolute pressure of the
steam system, or 5 psi, whichever is greater.
The gain on a control valve should never be
less than 0.5.
Avoid using the lower 10% and upper 20% of
the valve stroke. The valve is much easier to
control in the 10–80% range.
Generally, control-valve bodies are one size
less than the line size. If this causes the valve
body to be significantly less than the line size,
which would reduce the valve’s effective Cv.
then do not apply this generalization.

Flow characteristic selection

Here are some guidelines that are helpful in deciding
which type of flow characteristic is best-suited for a
particular application.

These are guidelines only, and should not be taken

as absolute recommendations:

Equal percentage:
when the major portion of the control-system
pressure drop is not through the valve
for temperature- and pressure-control loops

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 Linear:
in liquid-level or flow-control service
where the pressure drop across the valve is
expected to remain fairly constant
where the major portion of the control
system’s pressure drop is through the valve.

Quick-opening:
for frequent on/off service, such as in batch or
semi-continuous processes, or where an
“instantly” large flow is required, i.e., for
safety or deluge systems.

Materials of construction
Materials selection includes specifying the hard
body, trim, soft gasket, seal and packing materials.
As a minimum requirement, the body and trim should
match the material of the interconnecting piping.

In addition to customer preferences and cost

considerations, the nature of the fluid also affects
material selection. Be careful when handling erosive
and corrosive fluids.

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 Erosion may be slowed by hard-facing the valve
internals with nickel or cobalt-chromium alloys.
Considerations must be given for high- and low-
temperature services (>800°F and below freezing,
respectively).

···

For example, at high temperatures, valves are

subject to greater stress and leakage due to the
expansion of their internals. Liquids that flash
through a control valve may cool to subzero
temperatures. This is especially so when throttling
highpressure hydrocarbon liquids.

A flash calculation must be performed to check for

the outlet temperature at the lower pressure. In other
low-temperature service, such as with cryogenic
liquids, atmospheric moisture can cause the moving
components of the valve, such as the stem, to
freeze, rendering them inoperable.

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 Thus, these valves require insulation. The valve body
and the packing should be designed to withstand
high pressure. In high-pressure application (> 1,000
psi), graphite is used to reinforce soft packings to
prevent extrusion through small orifices.

Reduced-port valves are used more often than full-

size ports, because the former creates a pressure
drop to attain the correct Cv. Also, a reduced port is
less expensive since it fits into a smaller body. Avoid
specifying odd sizes of valves, for example, 1.25, 2.5,
3.5, 5 and 22 in. These less-common sizes are hard
to find and cost more than standard sizes.

Valves can be fitted with different end connections.

The RF (raised face) is commonly used; the RTJ
(ring-type joint) is found in some of the high-
pressure classes. Valves can be welded into place,
providing a leak-free connection This eliminates the
cost and weight of flanges, but may be problematic if
the valve has to be removed for service.

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 ···

Maintenance
Obviously, a poorly designed valve may require more
maintenance because it will be unable to function
adequately under the service conditions. Common
problems are wear of the valve body, actuator
diaphragm, seat and packing. Each one of these can
be reduced by selecting the proper style of valve and
its materials of construction.

For example, a valve handling entrained solids has to

be cleaned more often to remove debris. In this
instance, selecting a globe valve may not be
advisable, as debris can be drawn through the stem
seal, thus damaging it and restricting control. A
rotary valve may be a better choice.

Packing wear is caused by friction between the

packing and the valve stem. A sliding-stem valve can
often result in more wear than one with a rotary

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 stem, since the sliding stem can collect deposits,
and may drag them through the packing. Packing
wear is amplified in valves with a poor stem surface-
finish, due to high friction between the rough stem
and the packing.

Selection of a valve with a smoother stem surface

can help. The valve seat may suffer damage from
two sources: the flowing fluid and the plug itself. A
soft seat, sometimes necessary for tight shut-off,
can be eroded away if exposed to a fluid with
entrained solids.

A metal seat is recommended for such service,

otherwise, the soft seal should be placed such that it
is shielded from the main flow path. If the plug and
the seat are not in good contact, lapping the seat
may be a good option. Lapping, which applies only to
metal seats, a process where the plug and seat are
manually ground together so that they have a
matching surface finish, and, thus, tighter fit.
Selecting valves with some diagnostic features may
help to reduce maintenance.

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 ···

Smart valves and positioners relay valve signature

parameters (actuator pressure, stem travel, etc.) to
software, which uses them to calculate performance
indicators, such as packing-stem friction and torque.

Monitoring the signature can help to predict

maintenance requirements. To be on the safe side,
consult with maintenance and operations personnel
during valve selection and design.

A final caution: Sizing the valve properly is important

for both process and economical efficiency. A
widespread industry problem is the over-sizing of
control valves, which leads to poor control and
reduced service life.

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