Training Module THINKTANKcontrol Valve PDF
Training Module THINKTANKcontrol Valve PDF
Training Module THINKTANKcontrol Valve PDF
Self-Operated Valves:
Self-operated valves operate receiving energy
from fluid pressure or fluid temperature. It has
high responsibility but generally is not good at
accuracy.
Control Valves:
Control valves operate receiving energy from
compressed air, electric power, etc.
used with controllers and sensors. Control
valves and related equipment realizes
most accurate control.
Introduction
What Is A Control
Valve?
Controller
4-20mA
4-20mA
Pressure Sensor Pressure Transmitter D.P.
Transmitter
Orifice
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Example of Process Control
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Introduction
Typical Control Valve Assembly
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Features of Each Actuator Types
Pneumatic type Hydraulic type Motorized type
Response time Dead time is rather long. Dead time is short. Action No dead time. Action speed is slow
Action speed is fast.
speed is fast
Maintaining safety position at supply Possible by using integrated spring Difficult to maintain Can stop and maintain only the
fail time or connecting volume tank easily and position at an emergency time.
certainly.
Output power Middle for spring diaphragm type. Small for oil integrated type. Bigger than pneumatic type and oil
Big for piston cylinder type Big for oil separated installation type pressure type
Weatherproof and Exprosion proof Not necessary Should be considered Should be considered
Air piping or electric wiring Simple Simple for oil integrated type. Simple
Complicated for oil separated
installation
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Combination of Body and Actuator
Actuator Body
Pneumatic Globe
Pneumatic Pneumatic
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Cv Calculation
“ 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.
Flow rate of 60 degF ( 15.6 degC) clean water with the unit of US gal/min
at differential pressure of 1 psi and specific travel of valve.
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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 of the valve.
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Flow Characteristic
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Quick-Opening Flow Characteristic
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Selection of Flow Characteristic
Constant ∆P Linear
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Control Valves
“
Valve and Actuator Types
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:
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.
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Valve Bodies
Globe Valves
Single-Port Valve Bodies
Single-Ported Globe-Style
Valve Body
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Valve Bodies
Most Popular Type
Globe Valves
Single-Port Valve Bodies 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 type
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.
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Valve Bodies
Globe Type Control Valves
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Top and Bottom Guided valve
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Cage Valve
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High Capacity,
Cage-Guided Valve Bodies
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Angle Valve
Wetted parts design is simpler than general 2 way valves. So this type
is also advantageous for viscous fluid.
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Three-Way Valve
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Diaphragm Valve
• 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.
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Rotary Valves
Butterfly Valve Bodies
High-Performance
Butterfly Control Valve
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V-Notch Ball Control
Valve Bodies
Rotary-Shaft Control
Valve with V-Notch Ball
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Eccentric-Disk Control
Valve Bodies
Center of the plug rotating point is eccentric from the
center of valve body.
Eccentric-Disk
Rotary-Shaft Control Valve
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PTFE Valve
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PVC / Polypropylene Valve
Polypropylene: 80 deg C
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Ceramic Valve
Wetted part materials are all ceramics
All wetted parts are made with ceramics that resists most of
acids and alkalis.
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Valve Plugs
Types of Valve Plugs
Cage
Contoured plug
EQ% Linear
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Valve Plugs
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Cage-Guided
Characterization of Cage-Guided Valve Bodies
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End Connections
Control Valve End Connections
1 2 5 6
Thread type(S) Flat face type(FF) Groove type Fit- in type
Primarily for For cast iron valves for low To prevent leakage, For the same purpose as
connections of small pressure service for gas or vacuum those of the groove type
valves - 1 in. service.(Normally,the
(25mm) or less valve flange is female)
3 4 7 8
Raised face type(RF) Ring joint type(RJ) Socket welded type(SW) Butt welded type(BW)
For high-temperature high-
Most popular type for For high-temperature high- For the same purposes as
pressure service of ANSI
ANSI 600#,(JIS 40K) or pressure service those of the socket welded
900# or higher.For
lower type.Normally,for valves of
poisonous fluids,Normally,for
2½ in.(80mm)or larger
valves of 2 in.(50mm)or
smaller.
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Bonnets
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Bonnets
Extension Bonnets
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Packing
Control Valve Packing
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Packing
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Packing
Typical Valve
Stem Packing Assemblies
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Packing
PTFE V-Ring
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Packing
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Packing
Graphite Ribbon for Rotary Valves
Single PTFE V-Ring 300 psi 0 to 200°F 20.7 bar -18 to 93°C Betten Long Very Low
ENVIRO-SEAL Duplex 750 psi -50 to 450°F 51.7 bar -46 to 232°C Superior Very Long Low
ENVIRO-SEAL Graphite ULF 1500 psi 20 to 600°F 103 bar -7 to 315°C Superior Very Long Moderate
(1)The valves shown are only guidelines.These guidelines can be exceeded, but shortened packing life or increased leakage might
result.The temperature ratings apply to the actual packing temperature, not to the process temperature.
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Gaskets
Operable temperature Operable maximum pressur
Type Type No. Of gasket Composition Use
range(℃) e
Flat type Copper
V562 -196 to +260 150 kgf/cm2 Oil-inhibited
Monel Aluminium
V564(Monel) -5 to +566 ANSI 2500
Service Oil-inhibited
V567 -196 to +400 150 kgf/cm2
coper inhibited service
Sawtooth Type Material of valve
V540 0 to +200 20 kgf/cm2 S15C
body:FC20
Oil-inhibited
150 kgf/cm2
V542 V543 (SUS316L) -196 to +260 -196 to +566 Copper SUS316 service General
ANSI 2500
Service
V544 -196 to 450 ANSI 2500 SUS316L
V544(Monel) -196 to +566 ANSI 2500 Monel
Oil-inhibited
V547 -196 to 400 150 kgf/cm2 Aluminium copper-inhibited
service
Spiral shaped external SUS316+ For seat of unit-
V590 -100 to +500 ANSI 1600
pressure type Asbestos structure cage
SUS316L+
V590(SUS316L) -100 to +450 ANSI 1600
Asbestos or teflon
Others(special uses)
V1500 V1501 0 to 100 20 kgf/cm2 Asbestos For HLS,HTS(when
specified by
customer)
V1500AC V1501AC +100 to +260 10 kgf/cm2
V563 Teflon coating -196 to +260 ANSI 300 SUS316+ teflon Oil-inhibited with
special material
spur-water service
V543 Teflon coating -196 to +260 ANSI 300 SUS316+ teflon
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Gaskets
Examples on Uses of Gaskets
Spiral gasket
V8590
Spiral gasket
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Grease
Lubricator
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Valve Plug Guiding
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Valve Plug Guiding
Left view
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Valve Plug Guiding
5. Port Guiding
Right view
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Valve Plug Guiding
Restricted-Capacity
Control Valve Trim
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Actuators
“ Actuators
Pneumatically operated control valve actuators are the most popular type in use,
but electric, hydraulic, and manual actuators are also widely used.
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Actuators
1. Diaphragm Actuators
3/1L W0364/1L
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Actuators
1. Diaphragm Actuators
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Actuators
2. Piston Actuators
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Actuators
3. Electrohydraulic Actuators
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Actuators
4. Manual Actuators
W0595/1L W8176-1
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Actuators
5. Rack and Pinion Actuators
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Actuators
6. Electric Actuators
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Actuators
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.
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Actuators
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Actuators
3. When driving the valve via a lever mechanism(Butterfly
valves,FloWing valves)Valve:Direct action → Valve:Direct
action → Vane:Normal position Actuator:Direct
action Valve:Direct action → Vane:Reverse position
Actuator:Direct action
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Positioners
1. Pneumatic Positioners
2.Analog I/PPositioner
3. Digital Controller
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Positioners
1. Pneumatic Positioners:
Apneumatic signal (usually 3-15 psig) is supplied to the
positioner.
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Positioners
2.Analog I/PPositioner
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 digital products
cover three categories.
* Digital Non-Communicating
* HART
* Fieldbus
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Positioners
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Positioners
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Volume Booster
Volume Booster
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Other Accessories
Other Control Valve Accessories
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Other Accessories
Limit Switches
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Other Accessories
Solenoid Valve Manifold
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Other Accessories
Supply Pressure Regulator
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Other Accessories
Pneumatic Lock-Up Systems
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Other Accessories
Pneumatic Lock-Up Systems
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Other Accessories
Fail-Safe Systems for Piston Actuators
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Other Accessories
Electro-Pneumatic Transducers
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Other Accessories
Electro-Pneumatic Valve Positioners
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Other Accessories
“ 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.
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Seat Leakage Classifications
Standards and Approvals
Control Valve Seat Leakage Classifications
(In accordance with ANSI/FCI 70一2 and IEC 60534-4)
Maximum
Leakage class Designatio Test Testing Procedures Required for
Leakage Test Pressures Establishing Rating
n Medium
Allowable
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Seat Leakage Classifications
0.1% of rated
Ⅲ As above As above As above.
capacity
0.01% of rated
Ⅳ As above As above As above.
capacity
0.0005ml per
minute of water Pressure applied to valve inlet
per Max.service pressure after filling entire body cavity and
inch of orifice drop across valve connected piping with water and
diameter per psi plug,
Water at 10-52℃(50- stroking valve plug closed.Use net
Ⅴ differential(5 X Not to exceed ANSI
125℉) specified max. Actuator thrust,
10-12m3 per body rating, or lesser
second of water pressure by but no more, even if available
per mm of orifice agreement. during test.allow time for leakage
diameter per bar flow to stabilize.
differential).
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Cavitation and Flashing
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.
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Cavitation and Flashing
Comparison of Pressure
Profiles for High and Low Recovery Valves
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Cavitation and Flashing
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Noise Prediction
“ Noise Prediction
1. Aerodynamic
1. Calculate the total stream power in the process at the vena contracta.
4. Account for the transmission loss of the pipewall and restate the sound pressure at the outside
5. Account for distance and calculate the sound pressure level at the observer’s location
2. Hydrodynamic
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Noise Prediction
Noise Control
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Noise Prediction
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Noise Prediction
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Noise Prediction
Special Valve
Design to Eliminate Cavitation
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Noise Prediction
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Noise Prediction
Noise Summary
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Noise Prediction
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THANK YOU