Control Valves Training Material 2

FIDEC
Training Center
Control Valves
Category of Valves FIDEC
(Training Center)
Valves
Manual valves Automated valves These valves are

operated
automatically.
Modulating valves are

Modulating valves moreover categorized
into 2 types.
Self Operated valves Control valves

On-Off valves
Control valves
On-Off valves just put operate receiving
Self-operated valves
the flow “on” or “off” . energy from
operate receiving
On the other word, let compressed air,
energy from fluid
the flow medium run or electric power, etc.
pressure of fluid
stop. There types of used with controllers
temperature. It has
valves are mainly used and sensors. Control
high responsibility
for sequential control valves and related
but generally is not
or rough control like air equipment realizes
good at accuracy.
conditioning. most accurate control.
Control Valves
Introduction FIDEC
(Training Center)
What Is A Control Valve?

The control valve manipulates a flowing fluid, such as gas, steam, water, or
chemical compounds, to compensate for the load disturbance and keep the
regulated process variable as close as possible to the desired set point.
The control valve assembly typically consists of the:

* Valve body
* The internal trim parts
* An actuator to provide the motive power to operate the valve
* A variety of additional valve accessories, which can include positioners,
transducers, supply pressure regulators, manual operators, snubbers, or
limit switches.
Control Valves training@fidec.ir

Roles of control valves FIDEC
(Training Center)
Process
Sensor Control Valve Controller
parameters
Orifice, Flow
Flow
meter 4-20mA
4-20mA
Pressure Press.
D.P.
Transmitter Transmitter
Level
Level
Transmitter
Temp. Temperature
Transmitter Orifice
Control Valves
Example of process control FIDEC
(Training Center)
Flow control Pressure control

Boiler
FC Turbine
PC
Boiler
Boiler feed pomp
Minimum flow control valve T bi b
Turbine bypass valve
l
Level control Temperature control
Reactor TC
LC
Heat exchanger
Control Valves
Introduction FIDEC
(Training Center)
Typical Valve Assembly

Component parts FIDEC
(Training Center)
Actuator
Positioner
Convert electrical signal to

pneumatic signal so that
valve can operate using
pneumatic energy.
Body
Control valve travel so that
correct amount of fluid runs
inside valve.
Yamatake Standard
Single Seated Valve
Control Valves
Structure of actuator and valve body FIDEC
(Training Center)
Diaphragm
Convert pneumatic energy to force
Spring
Convert force to displacement
Gasket
Seal the space between
valve body and bonnet
Valve Plug
Valve Body Seat Ring
Trim modulates
flow passage to
control flow rate.
Control Valves
Introduction FIDEC
(Training Center)
Major Component of Typical Control Valve Body

Introduction Rain cap FIDEC
Eye bolt (Training Center)
Diaphragm
Spring
Actuator stem
Diaphragm case
Actuator Scale plate
Stem connector
Yoke
Packing flange
Packingg follower
Yoke claming nut
Gland packing
Valve stem
Bonnet
Stud bolt and nut
Gasket
Body Guide ring Trim
Guide bushing
Valve plug
Seat ring
Valve body
Combination of body and actuator FIDEC
(Training Center)
Control
valves
Actuator
Pneumatic Motorized Hydraulic
Body
Glove Angle Butterfly

Control Valves
Features of each actuator types FIDEC
(Training Center)
Pneumatic type Hydraulic type Motorized type
Response time Dead time is rather long. Dead time is short. Action No dead time. Action speed is
Action speed is fast. speed is fast slow
Maintaining safety position Possible by using integrated Difficult to maintain Can stop and maintain only
at supply fail time spring or connecting volume the position at an emergency
tank easily and certainly. time.
Output power Middle for spring diaphragm Small for oil integrated type. Bigger than pneumatic type
type. Big for piston cylinder Big for oil separated and oil pressure type
t
type. i t ll ti ttype
installation
Structure Simple Complicated Complicated
Weather proof and Exprosion Not necessary Should be considered Should be considered
proof
Air piping or electric wiring Simple Simple for oil integrated type. Simple
Complicated for oil separated
installation
Maintenance work Easy Complicated Complicated
Cost Reasonable Expensive Expensive
Control Valves
Features of each body types FIDEC
(Training Center)
Linear Glove valve 3-1. Single seated valve

motion
3-2. Top & Bottom guided valve
3-3. Cage valve
3-4. Angle valve
Control 3-5. Tree-way valve

Valves
3-6. Diaphragm valve
Gate valve
Rotary 3-7. Rotary valve

motion
3-8. Butterfly valve
Ball valve
Control Valves
Cv calculation FIDEC
(Training Center)
When you decide port size of control valve, you need to calculate required
Cv value with fluid condition given on control valve data sheet. Then, you
can specify appropriate Rated Cv value and port size.
At this chapter, most popular Cv calculation formula that is established by
FCI (Fluid Controls Institute, Inc.) is introduced.
What is Cv value ?
One of the popular coefficients that express flow capacity. Cv value us
defined as follows.
Fl
Flow rate off 60 degF
d F (15
(15.6
6 degC)
d C) clean
l water with
i h the
h uniti off US gal/
l/
min at differential pressure of 1 psi and specific travel of valve.
-Rated Cv value: Cv value at a valve is fully opened.
-Required Cv value: Cv value calculated with fluid condition
water 60degF
1 psi US gal/min
Control Valves
Introduction FIDEC
(Training Center)
Flow Control Characteristics

As the actuator moves the valve plug through its travel range, the unobstructed
flow area changes in size and shape depending on the contour of the valve plug.
When a constant pressure differential is maintained across the valve, the changing
relationship between percentage of maximum flow capacity and percentage of total
travel range can be portrayed , and is designated as the inherent flow characteristic
off the
th valve.
l
Commonly specified inherent flow characteristics include:

* Linear Flow Characteristic
* Equal-Percentage Flow Characteristics
* Quick-Opening Flow Characteristic

Introduction FIDEC
(Training Center)
Linear Flow Characteristic
Cv = K . L
(K: Constant, L: Valve plug travel)
Equal-Percentage Flow Characteristics
Inherent Flow Characteristics Curves

Introduction FIDEC
(Training Center)
Quick-Opening Flow Characteristic
Typical Construction to Provide Quick-Opening

Flow Characteristic

Introduction FIDEC
(Training Center)
Selection of Flow Characteristic
Liquid Level Systems

Introduction FIDEC
(Training Center)
Rangeability
“Rangeability” denotes the ratio between the maximum flow rate and the minimum flow
rate which can be controlled by a control valve.
Cv max imum
Inherent rangeability = Cv min imum

Control Valves FIDEC
(Training Center)
Valve and Actuator Types

Control Valves
The control valve regulates the rate of fluid flow as the position of the valve plug
or disk is changed by force from the actuator. To do this, the valve must:
* Contain the fluid without external leakage;

q
* Have adequate capacity
p y for the intended service;;
* Be capable of withstanding the erosive, corrosive, and temperature influences
of the process; and
* Incorporate appropriate end connections to mate with adjacent pipelines and
actuator attachment means to permit transmission of actuator thrust to the valve
plug stem or rotary shaft.

Valve Bodies FIDEC
(Training Center)
Globe Valves
Single-Port Valve Bodies
Single-Ported Globe-Style
Valve Body

Valve Bodies FIDEC
(Training Center)
Most Popular type•

Valve plug has only one seat to shut-of fluid•
Seat leakage is low even though it has metal •
seat
Unbalancing fluid force is higher than •
pressure balancing
p g type
yp
When required valve size is lower than 2 inch,•
This type is most advantageous because
small sized actuator can be mounted.
That means price is reasonable.•
When required size is larger than 2 inch, •
generally, price is not reasonable because the
larger the valve size is, the bigger the
actuators size is comparing single seated type
to pressure balancing type.

Valve Bodies FIDEC
(Training Center)
Gasket
Valve Plug
Valve Body
Seat Ring

Top and Bottom Guided valve FIDEC
(Training Center)
The valve plug is guided at top and •

bottom.
Pressure balanced type.•
This type is used mainly for oil refinery •
industry.
Generally, seat leakage is larger than •
single seated valves.

Cage valve FIDEC
(Training Center)
This type comes after single seated type in market.

Valve plug is guided by cage (shaped like pipe and set in
valve body. It has window that consists of flow
characteristics.)
Pressure balanced type is more popular than unbalanced
type.
For pressure balanced cage type, actuator size is smaller
than single seated type when body size is same.
Therefore price is more competitive than single seated
type when valve size larger than 3 inch or used with high-
high
pressure rating.
This type can reduce cavitation erosion and aerodynamic
noise that are typical control valve claim.
Generally, seat leakage is larger than single seated valve.
Seat ring Valve plug

Valve Bodies FIDEC
(Training Center)
High Capacity, Cage-Guided Valve Bodies
High Capacity Valve Body with Cage-Style Noise

Abatement Trim
Angle valve FIDEC
(Training Center)
Center of inlet and outlet of valves are right •

angle.
This type is advantageous for erosive or •
abrasive fluid.
Also used because of piping design •
advantage.
Wetted parts design is simpler than general 2 •
way valves. So this type is also advantageous
for viscous fluid
fluid.
Erosion: Destruction of valve bodies or trims

due to high fluid velocity
Abrasion: Erosion due to slurry that contains

solids or particles.

Tree-way valve FIDEC
(Training Center)
Three-Way Valve Bodies
Diverting type is used to separate flow to 2 way.•

Mixing type is used to mix 2 flow.•
Mainly used for temperature control.•
Mixing type Diverting type

Diaphragm Valve FIDEC
(Training Center)
•Elastic diaphragm made with rubber and PTFE modulate
the flow passage.
•Wetted parts can be lined with several materials (PTFE,
Glass, and rubbers). So this type is advantageous for
slurry or corrosive fluid.
•This type is cost effective.
Full open
Control
Full close
Control Valves
Valve Bodies FIDEC
(Training Center)
Rotary Valves
Butterfly Valve Bodies
A disk that is almost same diameter as

pipe size rotate so as to modulates flow.
Valve capacity is highest for all types of
valves.
Generally this type is used at pressure
Generally,
rating 300# or lower. For higher-pressure
rating, this type cannot be applied.
High-Performance
Butterfly Control Valve

Valve Bodies FIDEC
(Training Center)
V-Notch Ball Control Valve Bodies
Rotary-Shaft Control
Valve with V-Notch Ball

Eccentric-Disk Control Valve Bodies FIDEC
(Training Center)
Center of the plug rotating point is eccentric from the center of valve body.
CV capacity is bigger than that of other globe valves.
Fluid can be passed easily because of straight trough construction.
Eccentric-Disk
Rotary-Shaft Control Valve
PTFE Valve FIDEC
(Training Center)
A branch of single seated •

control valve.
Especially used for •
corrosive fluid.
All wetted parts are made •
with PTFE, which resist
most of acids and alkalis.
Body has rigid stainless •
casing to avoid warp with
Plug: PTFE with piping stress.
304ss core Applicable pressure and •
Bellows: PTFE temperature is limited.
Casing: SUS304 Max Operating •

Temperature: 140 deg C
Body: PTFE

PVC / Polypropylene Valve FIDEC
(Training Center)
A branch of single seated control valve.

Especially used for corrosive fluid.
All wetted parts are made with PVC or
Polypropylene, which resist most of
acids and alkalis
Applicable pressure and temperature
is limited.
Cheaper than PTFE valve
Max Operating Temperature:

PVC: 50 deg C,
Polypropylene: 80 deg C
Model VNP
Control Valves
Ceramic Valve FIDEC
(Training Center)
Wetted part materials are all ceramics •

All wetted parts are made with ceramics that •
resists most of acids and alkalis.
3.Highest abrasion resistance. •
4. There are application limitations for •
temperature, pressure and seat leakage class.
Ceramic
99% aluminum
ceramic or
Silicon carbide
ceramic
Model HMC CV < 4.0

Model HIC 13<CV<120 Aluminum ceramic: 70 deg C
Control Valves
Valve Plugs FIDEC
(Training Center)
Types of Valve Plugs
Cage
Plug for cage valve
Contoured plug
EQ% Linear

Valve Plugs FIDEC
(Training Center)

Cage-Guided FIDEC
(Training Center)
Characterization of Cage-Guided Valve Bodies
Characterized Cages for Globe-Style Valve Bodies

End Connections FIDEC
(Training Center)
Control Valve End Connections

End Connections FIDEC
(Training Center)

Bonnets FIDEC
(Training Center)
Valve Body Bonnets

The bonnet of a control valve is that part of the body
assembly through which the valve plug stem or rotary
shaft moves.
Typical Bonnet, Flange, and Stud Bolts

Bonnets FIDEC
(Training Center)
Extension Bonnets
Extension Bonnet Valve Body with

Fabricated Extension Bonnet
Packing FIDEC
(Training Center)
Control Valve Packing
Single PTFE V-Ring Packing

Packing FIDEC
(Training Center)
Comprehensive Packing Material Arrangements

for Globe-Style Valve Bodies

Packing FIDEC
(Training Center)
Typical Valve
Stem Packing Assemblies

Packing FIDEC
(Training Center)
PTFE V-Ring
Laminated and Filament Graphite
Single PTFE V-Ring Packing
ENVIRO-SEAL_ PTFE Packing
ENVIRO-SEAL PTFE Packing System

Packing FIDEC
(Training Center)
V-PTFE V7132Y #4519 y

yarn
Graphite (T2200) SM636 TK2006

Packing FIDEC
(Training Center)
Graphite Ribbon for Rotary Valves

Packing FIDEC
(Training Center)

Gaskets FIDEC
(Training Center)
Gaskets

Gaskets FIDEC
(Training Center)

Gaskets FIDEC
(Training Center)
Examples on Uses of Gaskets

Serrated metal gasket
Spiral gasket
Model HTS M d l ACP

Model
V543 V543 PTFE coated V8590

Serrated metal gasket Spiral gasket
Gaskets FIDEC
(Training Center)

Grease FIDEC
(Training Center)
Lubricator
PS6 #800 #400 #650

Valve Plug Guiding FIDEC
(Training Center)
Valve Plug Guiding
1. Cage Guiding

(Training Center)
2. Top Guiding

(Training Center)
3. Stem Guiding
Left view

(Training Center)
4. Top-and-Bottom Guiding

(Training Center)
5. Port Guiding
Right view

(Training Center)
Restricted-Capacity
Control Valve Trim
Adapter Method for Providing Reduced Flow Capacity

Actuators FIDEC
(Training Center)
Actuators
Pneumatically operated control valve actuators are the most popular type in use,
but electric, hydraulic, and manual actuators are also widely used.
The spring-and-diaphragm pneumatic actuator is most commonly specified due to

its dependability and simplicity of design. Pneumatically operated piston actuators
provide high stem force output for demanding service conditions.

Actuators FIDEC
(Training Center)
1. Diaphragm Actuators

Actuators FIDEC
(Training Center)
Field-Reversible Multi-Spring Actuator

Actuators FIDEC
(Training Center)
Diaphragm Actuator for Rotary Shaft Valves

Actuators FIDEC
(Training Center)
2. Piston Actuators
Control Valve with

Double-Acting Piston Actuator
Actuators FIDEC
(Training Center)
3. Electrohydraulic Actuators
Control Valve with Double-Acting Electrohydraulic

Actuator and Handwheel

Actuators FIDEC
(Training Center)
4. Manual Actuators
Typical Manual Actuators

Actuators FIDEC
(Training Center)
5. Rack and Pinion Actuators
Typical Rack and Pinion

Actuator

Actuators FIDEC
(Training Center)
6. Electric Actuators
Traditional electric actuator designs use an electric motor and some form of gear reduction
to move the valve. Through adaptation, these mechanisms have been used for continuous
control with varying degrees of success.

Actuators FIDEC
(Training Center)
7. Types (Directions) of Valve and Actuator Actions

Types of valve and actuator actions should be correctly selected for fail-safe plant
operation when the driving power (air supply) has failed. The type (direct and reverse)
are defined as follows:
(a) Direct action: Valve opens when driving power has failed.
(b) Reverse action: Valve closes when driving power has failed.

Actuators FIDEC
(Training Center)

Actuators FIDEC
(Training Center)

Actuators FIDEC
(Training Center)

Positioners FIDEC
(Training Center)
Control Valve Accessories

Positioners
Pneumatically operated valves depend on a positioner to take an input signal from a
process controller and convert it to valve travel. These instruments are available in three
configurations:
1. Pneumatic Positioners
2. Analog I/P Positioner
3. Digital Controller

Positioners FIDEC
(Training Center)
1. Pneumatic Positioners: A pneumatic signal (usually 3-15 psig) is supplied to the

positioner.

Positioners FIDEC
(Training Center)
2. Analog I/P Positioner

This positioner performs the same function as the one above, but uses electrical
current(usually 4-20 mA) instead of air as the input signal.
3. Digital Controller
Although this instrument functions very much as the Analog I/P described above,
it differs in that the electronic signal conversion is digital rather than analog. The
di it l products
digital d t cover th three categories.
t i
* Digital Non-Communicating
* HART
* Fieldbus

Positioners FIDEC
(Training Center)
Modern Control Valves

Utilizing Digital Valve Controllers

Positioners FIDEC
(Training Center)
Positioner Schematic for

Piston Actuator

Volume Booster FIDEC
(Training Center)
Volume Booster

Other Accessories FIDEC
(Training Center)
Other Control Valve Accessories
Top-Mounted Handwheel Top-Mounted Handwheel

for Direct-Acting Diaphragm Actuator for Reverse-Acting Diaphragm Actuator

(Training Center)
Limit Switches
Cam-Operated Limit Switches

(Training Center)
Solenoid Valve Manifold

(Training Center)
Supply Pressure Regulator
Supply Pressure Regulator

with Filter and Moisture Trap

(Training Center)
Pneumatic Lock-Up Systems

(Training Center)

(Training Center)
Fail-Safe Systems for Piston Actuators

(Training Center)
Electro-Pneumatic Transducers
Electro-Pneumatic Transducer Mounted on a Diaphragm-

Actuated Control Valve
(Training Center)
Electro-Pneumatic Valve Positioners

(Training Center)
Diagnostics
Digital valve controllers incorporate predefined instrument and valve diagnostics
within firmware to provide alerts if there are problems with instrument mounting,
electronics, hardware or valve performance.

Seat Leakage Classifications FIDEC
(Training Center)
Standards and Approvals

Control Valve Seat Leakage Classifications
(In accordance with ANSI/FCI 702 and IEC 60534-4)

(Training Center)

(Training Center)

Cavitation and Flashing FIDEC
(Training Center)
Cavitation and Flashing

Choked Flow Causes Flashing and Cavitation
The IEC liquid sizing standard calculates an allowable sizing pressure drop,

conditions of P1 and P2

may occur.
The change is from the liquid state to the vapor state and results from the
increase in fluid velocity at or just downstream of the greatest flow restriction,
normally the valve port.
Vena Contracta Illustration

(Training Center)
Comparison of Pressure
Profiles for High and Low Recovery Valves

(Training Center)
Typical Appearance of Typical Appearance of

Flashing Damage Cavitation Damage

Noise Prediction FIDEC
(Training Center)
Noise Prediction
1. Aerodynamic
The method defines five basic steps to a noise prediction:

1. Calculate the total stream power in the process at the vena contracta.
2. Determine the fraction of total power that is acoustic power
3. Convert acoustic power to sound pressure.

4. Account for the transmission loss of the pipewall and restate the sound
pressure at the outside surface of the pipe
5. Account for distance and calculate the sound pressure level at the
observer’s location
2. Hydrodynamic
(Training Center)
Noise Control
Valve Trim Design for Reducing Aerodynamic Noise

(Training Center)
Valve and Inline Diffuser Combination

(Training Center)
Valve and Vent

Diffuser Combination

(Training Center)
Special Valve
Design to Eliminate Cavitation

(Training Center)
Typical In-Line Silencer

(Training Center)
Noise Summary
Globe Style Valve

with Noise Abatement Cage for Aerodynamic Flow

(Training Center)
Ball Style Valve with Attenuator to Reduce

Hydrodynamic Noise

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FIDEC

Manual valves Automated valves These valves are

Modulating valves are

Self Operated valves Control valves

What Is A Control Valve?

The control valve assembly typically consists of the:

Control Valves training@fidec.ir

Flow control Pressure control

Level control Temperature control

Typical Valve Assembly

Convert electrical signal to

Major Component of Typical Control Valve Body

Pneumatic Motorized Hydraulic

Glove Angle Butterfly

Pneumatic type Hydraulic type Motorized type

Cost Reasonable Expensive Expensive

Linear Glove valve 3-1. Single seated valve

3-3. Cage valve

3-4. Angle valve

Control 3-5. Tree-way valve

Rotary 3-7. Rotary valve

Flow Control Characteristics

Commonly specified inherent flow characteristics include:

Control Valves training@fidec.ir

Linear Flow Characteristic

Equal-Percentage Flow Characteristics

Inherent Flow Characteristics Curves

Control Valves training@fidec.ir

Quick-Opening Flow Characteristic

Typical Construction to Provide Quick-Opening

Control Valves training@fidec.ir

Selection of Flow Characteristic

Liquid Level Systems

Control Valves training@fidec.ir

Control Valves training@fidec.ir

Valve and Actuator Types

* Contain the fluid without external leakage;

Control Valves training@fidec.ir

Control Valves training@fidec.ir

Most Popular type•

Control Valves training@fidec.ir

Control Valves training@fidec.ir

The valve plug is guided at top and •

Control Valves training@fidec.ir

 This type comes after single seated type in market.

Seat ring Valve plug

Control Valves training@fidec.ir

High Capacity, Cage-Guided Valve Bodies

High Capacity Valve Body with Cage-Style Noise

Center of inlet and outlet of valves are right •

Erosion: Destruction of valve bodies or trims

Abrasion: Erosion due to slurry that contains

Control Valves training@fidec.ir

Three-Way Valve Bodies

Diverting type is used to separate flow to 2 way.•

Mixing type Diverting type

 A disk that is almost same diameter as

Control Valves training@fidec.ir

V-Notch Ball Control Valve Bodies

This type comes after single seated type in market.

A disk that is almost same diameter as