Chapter 1: Instrumentation Equipment MODULE 8: Control Valves and Accessories

Chapter 1: INSTRUMENTATION L. ~t.
/IPMENT
Module 8: Control Valves and Accessories
Instrumentation & Control

Chulalongkofll University
CHAPTER 1: INSTRUMENTATION EQUIPMENT

MODULE 8: Control Valves and Accessories
MODULE OBJECTIVES: At the end of this module, you will be able to:
1.
State the combinations of pneumatic actuator and globe valve body required to provide:
a) air to open action; b) air to close action.
2.
State the three flow characteristics usually available for a globe valve. Sketch the flow characteristic
curve for each kind.
3.
State a typical application for each of the three flow characteristics and explain why it is used in that
application.
4.
State the effect of the unbalanced force on valve position and explain how, by giving an example,
bench setting would correct this problem.
5.
Briefly explain at least five advantages a positioner gives when it is used in conjunction with a
control valve.
6.
Explain the situations where the by-pass switch of the positioner should not be operated.
7.
Describe the failure mode of a control valve, when the valve configuration and positioner action are
given.
,
State the advantages of the following control valves: a) Y-ball valve; b) a rotating plug valve;
c) a diaphragm valve.
.
8.
9.
10.
11.
Explain, with a diagram, how a three-way solenoid valve can be used for ON/OFF control of a
pneumatic valve.
Explain the type and function of typical electric motor operated valves and state a typical application
for a Rotork, Limitorque and Hopkinson valve.
State why it is often advisable to use different sized valves in parallel when the process variable has
a very large range.
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C,~apter 1:
INSTRUMENTATION E(.,~,PMENT

Chulalongkorn University
Control Valves and Accessories

The final control element in a system is used to vary the flow of a manipulated variable in an attempt to
maintain a process parameter at a desired setpoint. Final control elements include control valves, metering
pumps, dampers and louvers, variable pitch fan blades, and electrically driven control devices.
The control vah&. is the most widely used type of final control element and it must perform satisfactorily
with a minimum amount of attention, even in severe conditions of temperature, pressure, corrosion and
contamination.
A control valve functions as variable resistance in a pipeline. It provides a pressure drop, called throttling,
which limits the flow through a pipeline.
There are many different kinds of control valves in common use: globe valves, butterfly valves, ball valves,
eccentric disc valves and diaphragm valves are some of the more popular types encountered.
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Chapter 1: INSTRUMENTA nON El./JIPMENT


Globe Valve
Globe valves are the most frequently encountered control valves in process plants. Figure 1 shows the
side view of a typical globe valve, which is named after its globular shaped valve body.
The globe valve consists of two main components:

1.
the valve body; which contains and regulates the fluid

flow, and
2.
the valve actuator, which converts electrical or

pressure energy into stem movement which changes
the regulating effect of the valve body.
- + - - PNEUMATIC
VALVE
ACTUATOR
VALVE BODY
ASSEMBLY
Figure 1: A Typical Globe Valve.
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Chapter 1: INSTRUMENTATION EQv,?MENT


Chulalongkom University
Globe Valve Body
r-----=-.,.....-
The globe valve body itself is made up of the

components shown in Figure 2.
PLUG STEM
,-L:J~ le~F11r~DS & NUTS
The bonnet assembly is the part of the valve

body through which the valve plug stem moves.
The bonnet provides a means of sealing against
leakage along the stem by using packing in the
packing box. Force is exerted by the stud and
nuts on the packing material to squeeze it
against the walls of the packing box and the
valve stem. This acts as a effective seal.
The valve stem extends through the bonnet to
permit positioning of the ~lve plug, and
therefore provide a variable restriction to the
fluid flow.
PACKING BOX
TEFLON PAC;~KI!!!NG~~-::::q~
R1NGSPACKlNG.SPRING
_ _ _.JlALVE BONNET
VALVE PLUG
VALVE
SEAT
Figure 2: Cross-Sectional View of a Globe Valve Body.
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Chapter 1: INSTRUMENTA TlON E.....JiPMENT

Globe valve bodies can be classified as either direct or reverse acting, as shown in Figure 3
...
,.".
VAlVE
...
: ,:IF
VALVE
VALVE
PLUG
...
STEM
PLUG
SEAT
a) Direct Acting
(b) Reverse Acting
Figure 3: A Simplified Diagram Showing Control Valve Body Action.
In a direct acting valve body, a downward movement of the valve plug stem results in the valve closing
In a reverse acting valve body, a downward movement of the valve plug stem results in the valve
opening
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Chapter 1: INSTRUMENTATION El.._,PMENT


Valve Actuators
A control valve actuator is a device which is used to drive the valve plug stem and therefore sets the
position of the plug with respect to the valve seat.
The most common valve actuator is the pneumatic diaphragm actuator. It is simple in construction and
very reliable. It operates by the injection of a single, low pressure air signal into the diaphragm housing.
The diaphragm housing is made up of two

sections. Between the two sections a flexible
diaphragm is installed.
The air pressure applied on the diaphragm
This force is
develops a working force.
transmitted to the actuator stem via the
diaphragm plate, which is a supportive metal
disk attached to the diaphragm.
The actuator spring provides a restoring force
which positions and returns the actuator stem.
The travel indicator (a pointer attached near the
stem connector) indicates the valve travel on the
indicator scale.
The actuator is supported rigidly on the valve
bonnet assembly by the yoke.
The actuator stem is connected by the stem
connector to the valve plug stem.
ACTUATOR INPUTSIGNAL.---~
DIAPHRAGM
DIAPHRAGM foL6.TE
ACTUATOR SPRIN'---
c::::::;~:-tlr-- ACTUATOR STEM
STEM CONNECTOR
TRAVEL SCALE
INDICATOR
TRAVEL INDICATOF\--1:!
--YOKE
Figure 4: A Typical Pneumatic Diaphragm Actuator.
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Chapter 1: INSTRUMENTATION EG/uIPMENT


Chula/ongkorn University
The diameter of the diaphragm plate determines the force that will be applied to the actuator stem. For
example, if the maximum input signal pressure is 100 kPa and the plate diameter is 30 cm, then:
Force applied to stem
=Pressure x Plate Area
= 100 kPa x 3.14 x (0.15)2 m 2
=7.07 KN (1590 Ib)

Although the signal pressure of 100 kPa seems to be fairly low, a substantial force can still be generated if
the diaphragm diameter is large.
Diaphragm actuators, as in the case of
valve bodies, can be classified as either
direct or reverse acting.
A direct acting actuator will cause the

actuator stem to be pushed downwards
as a result of applying signal air to the
top of the diaphragm (Figure 5(a)).
Retum Spring - - - '
The reverse acting actuator will push

the actuator stem upwards as signal air
is applied to the bottom of the
diaphragm (Figure 5(b)).
Diaphragm - - - -
Stem -------l1+1
. . . . - - - - - Yoke - - - - -.....
(a) Direct Acting
(b) Reverse Acting
Figure 5: Direct and Reverse Acting Actuators.
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Chapter 1. INSTRUMENTATION E(.,vIPMENT


Valve Action
Control valves can be built from various combinations of valve actuator and valve body. The combination
of actuator and valve body is usually chosen to provide a particular failure mode should the compressed
instrument air supply fail for any reason.
Any failure mode can be obtained with a
combination of direct or reverse acting
actuator and direct or reverse acting valve
body.
An air to close (A/C), and therefore fail
open valve, can be obtained with the
combination of a reverse acting actu,ator
and a reverse acting valve body or a direct
acting actuator and a direct acting valve
body. (Figure 6(a)).
Similarly, an air to open (A/O), and
therefore fail cl~ valve, can be obtained
with a combination of direct actuator and
reverse body or reverse actuator and girect
body (Figure 6(b)).
._--"'a..---..
Retum Spring - - "
Diaphragm - - - Stem ------1.(
l!!!!~----- Yoke -----~==
Figure 6(a)
Air to Close (A/C) Valve
Valve
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Figure 6(b)
Air to Open (A/O)
C,~apter 1: INSTRUMENTA TION E<"vlf'MENT

Below are all possible combinations of valve body and actuator and their failure modes.
Actuator
Valve Body
Valve Action
Failure Mode
Direct
Direct
Air to Close
Fail Open
Reverse
Reverse
Air to Close
Fail Open
Direct
Reverse
Air to Open
Fail Closed
Reverse
Direct
Air to Open
Fail Closed
Table 1: Summary of Valve Action and Failure Mode.

Note that often it is not possible to determine the over all action of a valve by observation alone. Whilst the
acr',on of actuators can be easily determined (usually by whether the air is supplied to the upper or lower
half of the housing), direct or reverse acting valve bodies are not always readily identifiable. ReferencE: to
the nameplate or flowsheet is usually necessary for positive identification.
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Chapter 1: INSTRUMENTA TION E.... _.PMENT


Globe Valve Flow Characteristics

The flow characteristic of a valve is the relationship between the flow capacity of the valve and the valve
plug position.
Flow capacity of a valve is the flowrate of the fluid through the valve under specified condition.
A standard method of defining a valve's flow capacity is to use the valve flow coefficient ~.
The valve flow coefficient is a function of flowrate of a specified fluid through the valve at a specified
pressure drop across the valve (,1P). (Usually expressed in U.S. gallons per minute at a ,1P of 1 psL)
Mathematically, f10wrate is related to valve coefficient
(CV) and pressure drop across the valve (,1P) by the
equation:
VALVE
STEM
PLUG
W~li'"''#"_rT-- .VALVE
PLUG
1l+
Q :: CV.Jt:-.P I S
where
Q
=flowrate of the fluid
S = fluid specific gravity

Therefore CV
=Q .Js I t:-.P
~llr~~~r--CAGE
The CV's of valves are determined experimentally by

~~lIri'.it---SEAT RING
measuring the flowrate of the water (Q) when the
-t----VALVE BODY
pressure drop across the valve (,1P) is 1 psi. CV's are
often used to compare valves with each other. The
valve with the higher CV will have a higher flow
capacity.
Figure 7: Valve Trim Components for a Globe Valve.
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Chapter 1: INSTRUMENTATION E(.,v,PMENT

Quick Opening Globe Valves

A typical quick opening valve plug is shown in Figure 8(a). The plug is designed to provide full capacity
with a very short stem travel.
,
Figure 8(b) illustrates the relationship between valve travel and CV of the quick opening valve. As can
be seen, quick opening valve plugs achieve 80% of maximum CV with only 50% valve travel.
,
~
Ie -
QUICK
OP~NING
II
10
J
I
J
II
J
I
0
Figure 8(a)
Quick Opening Valve Plug
~II
10
II
110
20
PER CENT OF RATtO TMIEL
Figure 8(b)
Flow Characteristic of Quick Opening Valves
Quick opening valves are used primarily in an ON/OFF manner in situations where rapid responses are
required.
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Chapter 1: INSTRUMENTATION E<. _.PMENT

Module 8: Control Valves and AccessNies

Shown in Figure 9 is the simplified poison injection system of a CANDU reactor shutdown system.
The triplicated poison injection valve arrangement increases the reliability of the system.
When a trip signal is received by the valves, they open to admit high pressure helium to the poison tank
and therefore inject poison into the reactor.
Total response time for the poison injection system is typically under 1.5 seconds.
hEUUM
SUPPLY
Figure 9: Simplified Poison Injection System for a CANDU nuclear reactor.
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Chapter 1: INSTRUMENTA TION E" ~.PMENT


Linear Globe Valves

A linear valve plug is designed to produce a linear relationship between valve travel and CV.
A typical linear valve plug is shown in Figure 10(a).
Figure 10(b) shows the flow characteristic of a linear valve plug.
V
/
V
1/
eo
LINEAR
/
/
1/
a:
'A!
/
0
Figure 10(a)
A Typical Linear Valve Plug
20
"
8Q
PI:Il CENT 01' RATED TRAvEL
100
Figure 10(b)
Flow Characteristic of Linear Valve Plug
To facilitate automatic control, a linear relationship between flQWr.cUe (not CV) and valve travel is desirable.
From Figure 10(b) it can be seen that for a linear valve plug, CV and valve travel exhibit a linear
Q = CV~!'>.P / S
relationship. Since flow rate (Q) is given as:
If ~P, which is the pressure drop across the valve, can be kept constant, the fiowrate will be linearly
proportional to the valve travel.
pagel-0-13
Chapter 1: INSTRUMENTATION E.... _.PMENT


One application of a linear globe valve is in the primary heat transport (PHT) feed and bleed system for PHT
pressure control.
Linear globe valves are used as feed valves to throttle the discharge of the pressurizing pumps.
The pressures at th~ discharge of the pressurizing pumps and the PHT system are fairly stable.
Therefore the pressure drop across each valve is essentially constant.
In this manner. the flow rate is linearly proportional to the valve travel.
~o
PRESSURE AT 8.6MPa
STORAGE
PRESSURE AT
APRROXIMATELY
10 MPa
FROM
BLEED COOLER
CVl
CV2
TO
HEAT
TRANSPORT
SYSTEM
LINEAR GLOBE VALVE
PRESSURIZING PUMP
Figure 11: Simplified PHT Feed and Bleed System.
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Chapter 1: INSTRUMENTATION E(.;UIPMENT

Equal Percentage Globe Valves

Figure 12(a) shows, a typical equal percentage valve plug. The valve flow characteristic is shown in Figure
12(b).
1
80
60
V
.I
J
~
..-
Figure 12(a): A Typical Equal

Percentage Valve Plug
./
.....
VeOUAL ......
P~RC~NT~GE
11
2 tt
10
60
40
PER CENT OF RATED TRAVEL
Figure 12(b): Flow Characteristic

of an Equal Percentage Valve.
An equal percentage valve gets its name because for equal increments in valve plug travel, the valve
coefficient will change by the same predetermined percentage over its original value.
For example, (refer to Figure 12(b)) if the valve plug position increases from 50% to 60% (an increase of
10%) the CV increases from 17.5% to 25%. For the same percentage (10%) increase in valve travel, say from
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Chapter 1: INSTRUMENTATION E. "IPMENT


60% to 70%, the CV increases from 25% to 36%, again a 43% increase when compared with initial CV of
25%.
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Chapter 1: INSTRUMENTA TION Eo ~JIPMENT


As with linear globe valves, equal percentage

valves are also used to throttle the discharge of
centrifugal pumps.
Equal percentage valves are used in situations
where there is a highly varying pressure drop
(~P) across the valve. Figure 13 shows a typical
centrifugal pump discharge pressure head curve
with associated pressure loss.
Recall that for a typical centrifugal pump, pump
head diminishes as flowrate increases. Also, as
flowrate increases, system pressure, loss (static
plus dynamic) increases.
From Figure 13, it can be seen that the difference
between the pump head curve (line 1) and
system pressure loss (line 2) curve is the
pressure (t~P) that is allocated to the valve, (line
3). In this case, ~P decreases rapidly as flowrate
increases.
Recall that flowrate across a valve is given by:
Q
PRESSURE(%)
1Iwr
CV(%)
__
100
100
75
50
25
25
=CV.JI1P/S
As ~P decreases, the valve coefficient CV has to

increase drastically to compensate for the
change in ~P if a linear relationship between
flowrate and valve travel. is to be maintained. An
equal percentage valve with flow characteristic as
shown in line 4 is used for this purpose. The
result is a linear relationship between flowrate and
10
1.
2.
3.
4.
5.
20
3O~50eo
PUMP HEAD YS FLOW

SYSTEM PRESSURE LOSS vS FLOW
AVAILABlE VALVE AP VI FLOW (1-,2)
DESIGN VALVE CV VI UFT
ACTUAL VALVE UFT VI FLOW
70
eo
llO
100
FLOWRATE (%)
Figure 13: A Typical Pump Head Curve With Losses.
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Chapter 1: INSTFiUMENTA TlON E:.. . .ilPMENT


valve lift as represented by line 5.
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Chapter 1: INSTRUMENTA TlON c",JIPMENT

Module B: Control Valves and Accessories

As application of equal percentage valves in CANDU nuclear plants is for the control of light water flow into
the Liquid Zone Control System.
CV1
To Other Zones
r------~J------.,
Equal % Globe Valve
J-r.~
Liquid
Header
Uquld Zone (In Core)
From Other z~o~n;es;:=::t~~~}---+-
Cold Service
Water
P1
Figure 14: A Simplified Zone Level Control Circuit.
In this system, the light water flow to the liquid zone is varied by valve CV1.
The outflow from the liquid zone is kept constant.
In order to vary the water level in the zone, the inflow has to be increased or decreased.
Valve CV1 has to control the inflow over the range 0.2 - 0.9 liters Isec.
Because of this relatively large flow change, the system (piping) losses will vary over a fairly wide range.
In an attempt to linearize the flow characteristic, and equal percentage valve is used as CV1.
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Chapter 1: INSTRUMENTA TION I:.. _ JIPMENT


Bench Setting
PNEUMATIC SIGNAL. (20-100KPa(O
Assume that we have an air to open

globe valve which consists of a
direct acting actuator and a reverse
acting valve body.
The valve is usually calibrated

RESULANT STEM FORCE DUE TO FLUID
such that a 20 kPa signal applied
to the actuator will cause the
valve to be fully closed, and a 100
kPa signal will cause it to be fully
open.
FLOW-.....
However, these settings do not
take into account the pressure
that is exerted by the process
'F\..UID FORCE ACTING ON VALVE PLUG
fluid on the valve plug when it is
installed in a flow system.
Figure 15: Air to Open Valve.
If the fluid pressure is hi;)h, the resultant force acting on the valve plug will be able to offset part of the
.
upward force exerted by the actuator.
Assume the upward force exerted on the valve plug by the fluid is equivalent to the downward force
generated by 10 kPa of the actuator pressure. When the signal pressure is 100 kPa, the net pressure on
the diaphragm is only (100 -10 kPa) 90 kPa. This will cause the valve to be open only to 90% rather than
the theoretical 100%.
Bench setting is the calibrating technique used to take into account the anticipated force exerted by the
process fluid. For the air to open valve described above, bench setting would result in the valve spring
being calibrated such that the valve is fully closed at 10 kPa and fully open at 90 kPa actuator pressure.
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Chaptor 1: INSTRUMENTATION E"'vIPMENT

Module 8: Control Valves and Acr.essories

Double-Ported Globe Valve

A globe valve can contain either one or two plugs. When there is only one plug, the valve is called single
ported (refer to Figure 2 at the beginning of this module). When there are two plugs as shown in Figure 16,
it is called a double-ported globe valve.
VElV SMALL RESULT A NT STEM FO~Ce
The double-ported valve arrangement

produces almost no unbalanced force
on the valve stem.
The fluid flows through the valve ports
in opposite directions and therefore
generates forces that off!5et each
other.
As a result, only a relatively small
actuator
force
is
needed
for
positioning the valve plugs.
This makes the double-ported globe
valve suitable for high pressure
applications.
fllOM HUll) FLOW
'2
". FORCE
~,
'~ "
SEAT/:o,:
--..
\~J
t'1
nOM FLU' D FLOW
11,
A double-ported globe valve does not

offer such complete shut off as a single
Figure 16: Double Seated Globe Valve.
ported unit, mainly because of the
difficulty
of
maintaining
correct
alignment and uniform wear and also differential expansion problems if the process is hot.
page 1 - 8 - 21
Chapter 1: INSTRUMENTATION c_JIPMENT


Valve Positioners
Pneumatic valve positioners are the most commonly used valve accessories. A valve positioner is a device
which will accurately position a control valve in accordance with the pneumatic control signal. With a
positioner, the control signal goes to the positioner instead of directly to the valve actuator. The positioner
outputs another pneumatic signal which operates the valve actuator.
The positioner compares the

control signal (the requested
valve position) with the actual
valve
position
through
the
mechanical feedback linkage.
If the valve position is incorrect,
the positioner will either load or
exhaust air from the valve
actuator until the correct valve
position is obtained.
A positioner requires both a
control signal and an instrument
supply air for normal operation.
Most positioners come equipped
with three gauges to indicate
supply air pressure, control
signal pressure and actuator
diaphragm (output) air pressure,.
PNEUMATIC AC'TlJATOR
--1
--
POSITIONER
CONTROL SIGNAL
2O-1llOKPa
BYPASS SWITCH
CONTROL VALVE
MECHANICAL
FEEDBACK
LINKAGE
lNll1'RUMENT
AIR SUPPLY
(250KPal
Figure 17: A Simplified Valve Positioner Installation.
page 1 - 8 - 22

Chapter 1" INSTRUMENTA TlON Et.,uIPMENT

Other advantages of the valve positioner include:

1.
Minimizing the effect of friction, hysteresis and deadband on the valve stem. With a high pressure
system, tighter valve stem packing is needed to prevent leakage and a high frictional force is
generated. With a positioner valve stem movements of as little as 25 ~m are possible.
2.
Enables signal range change. A positioner can amplify the incoming control signal when a greater
actuating force is needed. A 20-100 kPa control signal can be amplified to 40-200 kPa before being
applied to the actuator.
3.
Allows signal reversa'. A positioner can operate in either direct or reverse acting mode. In direct
acting mode, an increase in control signal pressure causes and increase in positioner output air
pressure. In reverse acting mode, an increase in control signal pressure causes a decrease in
positioner output air pressure. For example, in reverse mode, a 100 - 20 kPa actuator signal would
correspond to a 20 - 100 kPa control signal.
4.
Increases the speed of response of the actuator.

depends on:
(a) the actuator volume, and
(b) the f10wrate of the control signal air.
The speed of response of the valve actuator
The positioner has a larger output capacity than other pneumatic devices, sayan liP transducer
(typically 40 - 50 cfm vs 4 - 5 cfm). With a positioner, qUicker fill up of the actuator and therefore
faster speed of response can be achieved.
5.
Allows valve flow characteristic to be changed. Most valve positioners employ a rotating cam in the
feedback system. This cam can be changed to simulate different valve flow characteristics.
A linear globe valve can be used to respond in an equal percentage manner.
6.
Allows split range operation. In a split range control loop, one controller is used to drive two control
valves.
page 1 - 8 - 23
Chapter L iNSTRUMENTATION I:._JIPMENT


An example of a split-range control

loop is the wide range heat transport
(PHT) pressure control loop as shown
in Figure 18.
In this system, both valves use the
same 4 - 20 mA signal from the
controller.
However, the feed valve is AIC and
the bleed valve is Ala. (Note the
different range of signal the feed
and bleed valve responds to.)
Under normal conditions, I.e., PHT
pressure constant, both valves are
closed, I.e., signal at 63% for both
Split Range Operation

Heat
Transport
System
PT
LA-
PIC
..rl
y
I
_ _ ...J
+----i
Bleed Valve
AlO
valve~.
Linkage
Linkage
From Heat
Transport
System
4-20mA
HTS
Bleed
Circuit
38-63%
To Heat
.....---l~( I--....~ Transport
Feed Valve
System
AlC
-.-,;;:;=-
Figure 18: Split Range Control Loop for PHT Pressure Control by
If the pressure in the PHT system
Feed and Bleed.
starts to increase, the PT will send
an increasing signal to the
controller.
This results in an increasing control signal applied to both the bleed and the feed valve. The bleed valve
will open more, removing more 0 2 0 from the PHT system, while the feed valve stays closed. The net
result is the pressure in PHT system remains constant. The opposite occurs if the pressure decreases,
Le., decreasing signal to both valves - feed increases bleed decreases.
page 1 - 8 - 24
Chapter 1: INSTRUMENTA TION E",JIPMENT


Bypassing the Positioner

On most positioners, a bypass switch is available (see Figure 17). In the bypass mode, the positioner itself
is bypassed and the control signal is applied directly to the control valve actuator.
The bypass switch must be used with caution. If the positioner is amplifying the control signal, operating
the bypass switch win result in a lower pressure signal to be applied to the valve actllator. This will cause
an erroneous valve opening. Likewise, when the positioner is operating in reverse mode, switching to
bypass may result in the valve moving instantaneously from one extreme to the other. In practice, the
bypass switch is often removed after the positioner has been commissioned to avoid possible confusion
and misuse.
Failure Mode With Valve Positioner
With the addition of a v~lve positioner, the
operating mode ot a control valve could be
changed.
A globe valve which consists of a direct
acting actuator and a direct acting valve
body is shown in Figure 19.
With the positioner in direct mode, a 100
POSITIONEFl
OUTPUT
2O-100KPa
iZ
'--oII-_..;.C..;;,0;"tNj,,;.R.;.;;OL SIGNAL
POSITIONER ....
2lHOOKPa
Z Z Z Z
DIRECT ACTING
POSITIONER
kPa control signal will drive the valve to the :(;~~---INSTRUMENT AIR SUPPLY
fully closed p o s i t i o n . . .
The valve is therefore (signal) _air to c l o s e o v
and will fail open.
Figure 19: Air To Close Valve With Direct Acting Positioner.
pago 1 - 8 - 25

Chapter 1: INSTRUMENTA TlON E'. JIPMENT

However, when the positioner is in reverse mode as shown in Figure 20, a 20 - 100 kPa control signal will
cause the positioner to output a 100 - 20 kPa signal to the actuator.
In this case, a 20 kPa control
signal will cause the valve to be
fully closed (positioner output at
100 kPa)
whereas a 100 kPa control signal
will cause the valve to be fully
open (positioner output at 20
kPa).
The valve will be (signal) air to
open and fail open.
With
a
positioner
different
operating and failure modes can
be obtained.
POSiTIONER
OUTPUT
10o-200KPa
CONTROL SIGNAL
POSITIONER.t-..---2O-100KPa
REVERSE ACTING
POSITIONER .
INSTRUMENT AIR SUPFLY
Figure 20: Air To Close Valve With Reverse Acting Positioner.
page 1 - 8 - 26
Chapter 1: INSTRUMENTA TlON El./llIPMENT

Instrumentation 8. Control
Butterfly Valves
Butterfly valves are one of the most popl;llar types of rotary valve. A typical butterfly valve is shown in
Figure 21.
VANE
aODY
SHAfT
FLC
Figure 21: Typical Butterfly Valve.

The butterfly valve consists of a body, a vane or disc, a shaft supporting the disc and various seal and
bearings to accommodate shaft operation and leak-fight shutoff. In a butterfly valve, rotation of the disc
within the body controls flUid flow.
Advantages of Butterfly Valves
Of all the valve types, a butterfly valve contains the least amount of body material. This is important when
the valve has to be manufactured from expensive material such as stainless steel. Another advantage of
butterfly valves is that the valve body occupies a minimal amount of flow line space. For applications
where large isolation valves are required, butterfly valves are the least expensive.
page 1 - 8 - 27
Chapter 1: INSTRUMENTA TION E_JIPM~NT

Module 8: Control Valves and Accessones

Application of Butterfly Valves

In industrial applications butterfly valves are primarily used for ON/OFF control associated with low static
pressure, high flowrate situations.
An example of such an application is in the
condenser cooling water system of a 500 MW
generating stations, shown in Figure 22.
In this system circulating pumps P1 and P2
provide a flow of approximately 25,000 kg/s
through the three condensers.
The individual condensers can be isolated
independently
using
motorized
valves
MV101-106 and manual valves V3-8. All of
these valvp.s are 72 inch butterfly valves.
As well, the whole bank of condensers can
be isolated from the pump discharge by
motorized valves MV1 and MV2, also
butterfly type, but 96 inches in size. In this
application, the butterfly valves allow
isolation at a relatively low cost considering
the large sizes involved.
"""0'
V5
V6
V7
96" B:.rrref.lFLY /
"'" I
VALve
"
CONDENSOR COCUNG
WATER PUMP
Figure 22: Condenser Cooling Water System of a

500 MW generating station.
---------------------.,-~..,-.-----------------page 1 - 8 - 28
Chaptel 1: INSTRUMEN7ATION E: ... JIPMENT

Instrumentation 8. Control
Ball Valves
The ball valve gets its name from the sphericai shape of its rotating plug.
As with the butterfly valve, the ball valve also rotates about a central shaft. Usually, a quarter turn is
sufficient to position the valve from fully closed to fully open. Figure 23 shows a typical full ball valve.
Figure 24: A Typical V-Ball Valve.
Figure 23: A Typical Full-Ball Valve.
To obtain a specific flow characteristic during throttling, the opening of the ball valve plug can be shaped
or contoured, as in the case of the V-ball shown in Figure 24.
One advantage of the V-ball valve is its high flow capacity when fully open. Little restriction is imposed by
the valve when it is open. In partially open (throttling) position, it has minimal interference with the f~ow
stream and therefore provides good control characteristics and wear resistance. In industrial applications,
V-ball valves are used in locations where good corrosion and erosion resistance are required.
page 1 - 8 - 29
Chapter 1: INSTRUMENTA nON E~ ..JIPMENT


Eccentric - Rotating Plug Valves

The eccentric-rotating plug valve has the advantages of the butterfly and ball valve with the ad~ed
advantage of positive seating and therefore tight shut-off. Figure 25 shows the cross-sectional view of an
eccentric rotating plug valve.
VALVE DISC (PLUG)
~-:t=:::-
Figure 25: An Eccentric Rotating Plug Valve.

The arm which directly supports the valve plug is slightly flexible so that when it is rotated against the seat,
it will bend or flex to compensate for minor misalignment. The eccentric rotating valve covers a large
percentage of process control requirements and is fairly widely used in large process systems.
page 1 - 8 - 30
Chapter 1. INSTRUMENTATION E:",JIPMENT


Chula/ongkorn University
Diaphragm (Saunders) Valve

The diaphragm valve, shown in Figure 26 has a straight through construction with a leak-tight closure. No
packing or seal assembly is required in the valve stem to prevent leakage. Flow control is achieved by
pressing a flexible diaphragm against a weir formed in the body wall.
- + - - - - - - - - STEM
\.-.-----+-
WEll
CLOSE!)
THlOTTUNG
OPeN
Figure 26: A Typical Diaphragm Valve.

The flow characteristic of a diaphragm valve approximates CI quick open valve. Materials used for the
diaphragm vary with conditions of flow, temperature, pressure and type of fluid. Plastic, tin, synthetic and
natural rubbers can be used. The diaphragm is chosen such that erosion caused by crud formation is
minimized and at the same time provides a leak-tight shut-off.
pagel-8-31
Chapter 1: INSTRUMENTATION l JIPMENT


Solenoid Valves
A solenoid valve is an electrically
operated
valve
where
an
electromagnet is used as an actuator
to change the valve state.
Solenoid valves are USE'd only in an
ON/OFF manner.
In a two-way solenoid valve (shown in
Figure 27), the valve is open when the
solenoid coil is energized.
The energized solenoid coil acts as an
electromagnet which pulls the plunger
and the valve disc upwards.
II
The valve is closed when the coil is
de-energized. The closing action of
the valve is achieved by the weight of
the plunger, valve stem and disc.
Once the disc comes close to its seat,
flow (from left hand side) will snap
the valve tightly shut.
\ -_ _- - - - - - COVER NUT
CONOUIT OPENING
;@~~3-'i~---_::eolL.
[~-----of"\,UNGR
Ii'
~:CENTERING WASHER
l~l~~il~:==-STOP
11,...----
~o!rJ;J~-..
WA!WlER
'AllIE STEM
VAL.VE BOOY
"'LVE DISC
V/JJ.VE SEAT
Figure 27: A Two-Way Solenoid Valve.
page 1 - 832
Chapter 1: INSTRUMENTA TION t. . ~IPMENT


In a three-way solenoid valve, as illustrated in Figure 28, energizing the solenoid coil causes the valve to
open from Port 1 to Port 2 while de-energizing the coil causes the valve to open from Port 2 to 3.
SOLENOID ACTUATOR
..
SOLENOID ENERGIZED
-.
SOLENOID DE-ENERGIZED
1
3
Figure 28: A Three-Way Solenoid Valve.
A solenoid valve is often used in conjunction with a diaphragm control valve to obtain ON/OFF valve
operation with an electrically applied signal.
The arrangement, depending on the valve size, may be much less expensive and faster responding than
using an all electric control valve.
pagel-B-33
Chapter I: tNSTRUMENTATION f,. ,tPMENT

Module 8: Control Valv&s and Accessories

Figure 29 shows an ON/OFF application of a three-way solenoid valve used to operate an A/O pneumatically
actuated valve.
SOLENOID
VALVE
.--""""'--CIIo--~~--o
All SUPPlY
100 kPa{g)
VENT TO
ATMOSPHERE
AlO
Figure 29: ON/OFF Application of a Solenoid Valve.
When the solenoid valve is energized, 100 kPa(g) is applied to the A/O valve, keeping it fUlly open.
When the solenoid valve is de,energized, the air supply (100 kPa(g)) is cut off, and simultaneously the
pressure trapped between the two valves is vented to atmosphere. This allows the A/O valve to go fully
closed.
page1-8-34
Chapter 1: INSTRUMEIJTA TlON E", "IPMENT


Motorized Valves
Motor driven valves are often used to isolate pneumatic actuator control valves and other equipment. A
typical motor driven actuator has a reversible, 3 phase electric motor which drives the valve between two
predetermined position limiters.
~------ROTATING VALVE
The majority of motorized valves are parallel

slide gate valve, as shown in Figure 30.
For this kind of valve, the sliding gate lowers as
the valve stem is rotated.
A spring between the two parallel gates exerts a
force against the fluid flows and therefore
maintains a leak tight seal during isolation.
STEM
It-lll~-----t--- SPRING
It-Ji----+--
Many different designs of motor driven gate valve

are used in process industries, ail of them work on
essentially the same principle discussed above.
The most frequently encountered types are referred
to by their brand names, such as Limitorque,
Rotork, and Hopldnson.
DISK
Figure 30: A Parallel Slide Gate Valve Body Assembly.
page 1 - 8 -35
Chapter 1: INSTRUMENTATION L

Chula/ongkorn UnivEirsity
AII __I '_
t'1.
"' __
__ I 1/_',,
,.J
)IPMENT
"'
: __
St6am
Figure 31 illustrates a typical motor drivel'l

valve installations on the steam generator
system of a CANDU nuclear station.
Steam
Ge.nerator
SG1
Limitorque valves MV1 and MV2 are

( Hopkinson
CV1
used to isolate the boiler from the heat
transport system for maintenance or in
case of boiler tube failure.
MV3
Mve CV2
Feedwater
The boiler level for any steam condition
is controlled by manipulating the Heal
MV4
MV1
TO
3
pneumatic Transport
feedwater inflow using
$':::0f-l1lQ--'"
M( CV3
SYSlem
~~_-,
actuator control valves CV1, CV2 and
MV5
... Rotork
MV2
CV3.
All three boilers in the bank are
'-.lim~OrqUs
controlled simultaneously by the same
set of valves.
Figure 31: Motorized Valve Installations in a CANDU
At normal power levels, one of CV2 or
CV3 (A/O, 10" doubled-ported giobe
Steam Generator System.
valves) provides feedwater control, the
other valve is held closed and kept as a
backup.
At low power levels, finer control of feedwater flow is required. The system is adjusted such that below
10% full power CV1 (A/C, 2" globe valve) provides feedwater flow control.
Above 10% full power, CV1 is fully open and either CV2 or CV3 takes over, giving a higher flow capacity.
During normal operation, Rotork valves MV6 and MV7 are held open, but can be used to isolate the
feedwater control valves in case of a failure.
page 1 - 8 - 36

Chula/ongkarn UnivelSity
Chaprer 1: INSTRUMENTATION L_JIPMENT

Although the same set of feedwater valves are used to control the feedwater inflow to three boilers, the
boilers might produce steam at different rates (due to blocked U-tubes or sludge and scale formation) and
cause feedwater level between boilers to vary. To make sure that all three boilers are at the same level,
Hopkinson valves MV3, MV4, and MV5 are used, one for each boiler. These valves are operated until ~he
feedwater levels on the three boilers are identical. In this case, Hopkinson valves are used for trimming the
flow to each boiler independently, as well as providing the means of isolating the boiler from the feedwater
circuit.
Use of Different Sized Valves in Parallel
Many industrial processes have a large range of controlled flow requirements between 0% and 100% of
the controllable range, boiler level control is a typical example. The feed flow to the boiler must be
adjusted to maintain boiler !evel at the setpoint over the entire range of possible steam flows i.e.,
feedwater and steam flows mu~t always be in mass balance.
The volume 01 feedwater required at full power conditions is large typically hundreds of kilograms per
second of feedwater per boiler - and necessitates the use of a large CV valve to meet the CV flow
requirements (10" or 25 em is typical}.
If just one valve, capable of meeting the 100% requirement, was used control at low power (low flow)
levels would be imprecise. To obviate this disadvantage, two valves are provided, one with 100%
capahility and another with 10-25% capability, in parallel.
In operation of this type of system requires the smaller valve to open to its maximum whilst the larger
valve remains closed. As the small valve reaches its maximum opening (or perhaps just before fully
open) the large valve commences to take up the flow.
page 1 - 8 37
Chapter 1: INSTRUMENTA TlON i:. _ APMENT

Instrumentatio', & Control

Boiler Level Control

There are two options for the small valves
when the large valves are fully open:
remains fully open,
reclose (in order to

erosive wear)
avoid
2o-100kPa
excessive
A/O
When the large valves close the reverse

actions follow (see Figure 32).
The method of achieving this operation
differs between various in~tallations, but in
general the operation can be achieved
basically as follows.
10"
2o-100kPa
To
Frorr--1
Feed
Pumps
Boiler
AlO
Figure 32: Representative Boiler Level Control Scheme.
The boiler level controller (LC) has a 100% output range of 4 - 20 mA (16 mA span). The small valve
requirement is to go to the fully open position at 10% ,"ange i.e., after LC Olltput has increased by 1.6 mA to
5.6 mAo By amplifying the LC output signal by a factor of 10 the signal applied to the small valve lIP is now
4 - 20 mA or an LC output of 4 - 5.6 mA i.e., the valve will stroke tully open.
Until this time the large valve should remain closed i.e., we require no valve movement until the large valve
lIP's input exceeds 5.6 mAo This can be achieved by a calibration adjustment to the positioner, a necessary
item of equipment, fitted to the large valve. In actual practice the large valve would probably be adjuste~ to
commence opening slightly below 5.6 mA to avoid a "step" in the flow pattern. (See Figure 33).
page 1 - 8 - 38

Chapter ,: INSTRUMENTATION b.JIPMENT

Fine and Course System Control of Boiler Feed Water

An absence of this parallel valving arrangement can lead to serious control problems such as those
contributing in part to the accident at Chernobyl. At Chernobyl, the operator was attempting to control
water level in the steam drum at low power levels with a single, 100% capacity valve. This caused wide
fluctuations in boiler level which, since it was a boiling water reactor, caused severe problems with
reactivity control.
Small Valve
;<
Large Valve
Valve
Opening
4mA
5.6 rnA
20mA
LC Output Signal
Figure 33: Boiler Feedwater Valve Control Logic.
page 1 - 8 - 39

Chapter 1: Instrumentation Equipment MODULE 8: Control Valves and Accessories

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Chapter 1: Instrumentation Equipment MODULE 8: Control Valves and Accessories

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Chapter 1: INSTRUMENTATION L. ~t.

Instrumentation & Control