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CHARACTERISTICS
Foreword
Welcome to value-conscious company. We are proud of the advanced engineering and
quality construction of each equipment we manufacture.
This manual explains the working of equipment. Please read it thoroughly and have all
the occupants follow the instructions carefully. Doing so will help you enjoy many years
of safe and trouble free operation.
When it comes to service remember that K.C. Engineers knows your equipment best
and is interested in your complete satisfaction. We will provide the quality maintenance
and any other assistance you may require.
All the information and specifications in this manual are current at the time of printing.
However, Because of K.C. Engineers policy of continual product improvement we
reserve the right to make changes at any time without notice.
Please note that this manual explains all about the equipment including options.
Therefore you may find some explanations for options not installed on your equipment.
You must follow the instructions and maintenance instructions given in the manual
carefully to avoid possible injury or damage. Proper maintenance will help ensure
maximum performance, greater reliability and longer life for the product.
K.C. Engineers
Contents
1. Objective
. 1
2. Introduction
. 1
3. Description
. 2
4. Utilities Required
. 3
. 3
6. Troubleshooting
. 3
. 4
2. Theory
. 4
3. Experimental Procedure
. 5
. 5
5. Nomenclature
. 6
6. References
. 6
. 7
2. Theory
. 7
3. Experimental Procedure
. 8
. 8
5. Nomenclature
. 9
6. References
. 9
. 10
2. Theory
. 10
3. Experimental Procedure
. 10
. 11
5. Nomenclature
. 11
6. References
. 11
. 12
2. Theory
. 12
3. Experimental Procedure
. 12
. 13
5. Nomenclature
. 13
6. References
. 13
. 15
2. Theory
. 15
3. Experimental Procedure
. 15
. 16
5. Nomenclature
. 16
6. References
. 16
1. OBJECTIVE:
To study Control Valve Characteristics
2. INTRODUCTION:
VALVE ACTION & ACTUATOR MECHANISM
If a control valve is used to control fluid flow, some mechanism must physically open
or close the valve. Different types of actuators are used to control the stem travel of the
valve, like electrical actuators, pneumatic actuator, Hydraulic actuators etc. In present
set-up, pneumatic actuators are used for Control Valves. Spring opposed diaphragm
actuator positions the valve plug in response to the controller signals. Mostly the
controller signals are in the range of 3-15 psig. There are two types of actuators
described below:
i) Direct acting actuator (Air to Close):
Direct acting actuators basically consist of a pressure tight housing sealed by a
flexible fabric reinforced elastomer diaphragm. A diaphragm plate is held against the
diaphragm by a heavy compression spring. Signal air pressure is applied to upper
diaphragm case that exerts force on the diaphragm and the actuator assembly. By
selecting proper spring rate or stiffness, load carrying capacity, and initial compression,
desired stem displacement can be obtained for any given input signal.
ii) Reverse acting actuator (Air to open):
In case of reverse acting actuators the stem gets retracted with increase in pressure.
Flow changes by a constant percentage of its instantaneous value for each unit of
valve lift.
Q = be ay
Q
valve opening
a and b=
constants
log R
x y
Q = Qo e
y max
Qo
ymax
Valve opening
Constant
3. DESCRIPTION:
The present set-up consists of two Nos. Control Valves with Pneumatic Actuators. One
Control Valve is with Equal % Characteristics (air to close type) and second is with
Linear Characteristics (air to open type). Apparatus is self-contained water recirculating unit (except compressed air supply, is to be provided from user end). Water
from Sump Tank is sucked and delivered to a Constant Level Overhead Tank by means
of a Centrifugal Pump. Water flows back from Overhead Tank to Sump Tank through
the control valve.
Each Control Valve is provided with a Ball Valve at the inlet. Flow rate of water,
passing through the Control Valve is measured with the help of Rotameter. A common
Water Manometer is provided for the measurement of Water Pressure Head at the inlet
of Control Valve. As outlet of Control Valve is open to the atmosphere, the pressure at
inlet of Control Valve is considered as Pressure Drop (P) across the valve.
Change in the Stem Travel/Position of Control Valve results in change in flow through
the Control Valve. This adjustment is done by regulating the Air Pressure inside the
diaphragm of Control Valve (3 to 15 psig). For this purpose a Pressure Regulator with
Pressure Gauge is provided in Pneumatic Line. Pressure Gauge facilitates to get direct
reading of Pressure inside the diaphragm of Control Valve. Individual ball valves are
provided to actuate the Pneumatic line for individual Control Valve. For detecting the
Stem Travel/Position, scale is provided on each Control Valve.
4.
UTILITIES REQUIRED:
Electricity Supply:
Single phase, 220 VAC, 50 Hz, 5-15 amp socket with earth
connection.
5.
6.
TROUBLESHOOTING:
1.
If pump gets jam, open the back cover of pump & rotate the shaft manually.
EXPERIMENT NO. 1:
1.
AIM:
To determine flow coefficient Cv of the control valves.
2.
THEORY:
A Control Valve is used to control the flow rate in a fluid delivery system to control
the process. There is a close relation between the pressure and the flow rate in fluid
stream passing through pipe so that if pressure is changed, the flow rate will also be
changed. A Control Valve changes the flow rate by changing the pressure in the flow
system because it introduces the constriction in the delivery system. So we can say
that the flow rate through the constriction can be given as:
Q=
K
P
A most important factor associated with control valve is the correction K of the above
equation. This correction factor allows selection of proper size of valve to
accommodate the rate of flow that the system must support. This correction factor is
called as valve coefficient and is used in valve sizing.
Q = Kv
v
G
KV = 0.856Cv
G
P
C v = 1.16 Q
Where:
Q
3.
EXPERIMENTAL PROCEDURE:
1. Start the set up for Control Valve of Equal % Characteristics.
2. Open Pneumatic Line for the Control Valve.
3. Open the Control Valve fully. As the Control Valve is Air to close so pressure in
diaphragm should be 0 psig.
4. Adjust the Rotameter for 500 LPH flow by regulating the valve provided at the
inlet line of the Control Valve and Wait for 5 minutes to steady the flow.
5. Record the Manometer reading in mm of water.
6. Record the Rotameter reading.
7. Increase the pressure slowly and record the manometer & Rotameter reading up
to 15 Psi.
4.
P, mm of H2O
Q, LPH
CALCULATIONS:
C v = 1.16 Q
G
= ---------------------P
Conduct the experiment for Linear Control Valve. As the Linear Control Valve is Air
to Open, so Pressure in diaphragm should be more than 15 psig. Adjust this pressure
in diaphragm by operating the Pressure Regulator. Do not exceed this pressure more
than 20 psig.
5.
6.
NOMENCLATURE:
Cv
REFERENCES:
1. Donald R. Coughanowr, Process System Analysis and Control, 2nd ed.,
McGraw Hill, NY, 1991, Page 305-309.
EXPERIMENT NO. 2:
2. THEORY:
VALVE CHARACTERISTICS:
The amount of fluid passing through a valve at any time depends upon the opening
between the plug and seat. Hence there is relationship between stem position, plug
position, and the rate of flow, which is described in terms of flow characteristics of a
valve. Inherent and installed are two types of flow characteristics of a Control Valve.
INHERENT CHARACTERISTICS:
The inherent flow characteristic of control valve is the relation between the flow and
the valve travel at constant pressure drop across the valve. Following are the inherent
characteristics for different types of valves.
Flow %
of Maximum
100
90
80
70
Quick Opening
60
50
40
Linear
30
20
10
Equal
%
0
0 10
20 30 40 50 60 70 80 90 100
VALVE LIFT
% OF FULL LIFT
3.
EXPERIMENTAL PROCEDURE:
1. Start the set-up for Linear Control Valve.
2. Open Pneumatic Line for the Control Valve.
3. Open the Control Valve fully. As the Control Valve is Air to open so pressure in
diaphragm should be 15 psig.
4. Adjust the Rotameter for 500 LPH flow by regulating the valve provided at the
inlet line of the Control Valve.
5. Wait for 5 minutes to steady the flow.
6. Record the Manometer reading in mm of water.
7. Record the Rotameter reading.
8. Now slowly decrease the air pressure by regulator so that the stem travel towards
closing position becomes 2 mm.
9. The pressure drop across the valve will increase. Throttle the regulatory valve at
the inlet of the Control Valve to maintain Pressure Drop constant.
10. Again note down the reading of Rotameter and stem travel.
11. Repeat the procedure and take the readings at each 2mm stem travel till the valve
is fully closed (Pressure upto 0 psig).
12. Plot the graph of valve coefficient versus lift to show inherent characteristic of the
control valve.
13. Conduct the same procedure for other two valves too.
4.
Stem lift in mm
14
12
10
Q, LPH
P,mmH2O
CALCULATIONS:
C v = 1.16 Q
G
= ---------------------P
Conduct the experiment for other two valves. As the Linear Control Valve is Air to
Close, so Pressure in diaphragm should be 0 psig. Repeat the experimental procedure
same as above, but pressure in the diaphragm will be increased gradually.
5.
6.
NOMENCLATURE:
Cv
REFERENCES:
1. Peter Harriott, Process Control, 19th ed., McGraw Hill, NY, 2000, Page 194198.
EXPERIMENT NO.3:
2. THEORY:
VALVE CHARACTERISTICS:
The amount of fluid passing through a valve at any time depends upon the opening
between the plug and seat. Hence there is relationship between stem position, plug
position, and the rate of flow, which is described in terms of flow characteristics of a
valve. Inherent and installed are two types of flow characteristics of a Control Valve.
INSTALLED CHARACTERISTICS:
The Installed characteristics of the valves described are subject to distortion due to
variations in pressure drop with flow. Line resistance distorts linear characteristics
towards that of quick opening valve and equal % to that of linear.
3. EXPERIMENTAL PROCEDURE:
1. Start the set-up for Equal % Control Valve.
2. Open Pneumatic Line for the Control Valve.
3. Open the Control Valve fully. As the Control Valve is Air to Close so pressure in
diaphragm should be 0 psig.
4. Adjust the Rotameter for 500 LPH flow by regulating the valve provided at the inlet
line of the Control Valve.
5. Wait for 5 minutes to steady the flow.
6. Record the Manometer reading in mm of water.
7. Record the Rotameter reading.
8. Now slowly increase the air pressure by regulator so that the stem travel towards
closing position becomes 2 mm.
9. Wait for 5 minutes to steady the flow and note down the reading of Rotameter,
Manometer and stem travel.
Control Valve Characteristics (Two Valves)
10
10. Repeat the procedure and take the readings at each 2 mm stem travel till the valve is
fully closed (Pressure upto 15 psig).
11. Plot the graph of valve coefficient versus lift to show Installed characteristic of the
control valve.
12. Plot the graph of the flow versus lift.
14
12
10
Q, LPH
P, mm of H2O
CALCULATIONS:
C v = 1.16 Q
G
= ---------------------P
5.
6.
NOMENCLATURE:
Cv
REFERENCES:
1. Donald R. Coughanowr, Process System Analysis and Control, 2nd ed.,
McGraw Hill, NY, 1991, Page 309-310.
11
EXPERIMENT NO. 4:
1.
AIM:
To study the hysteresis of the control valve
2.
THEORY:
Hysteresis is a predictable error resulting from the differences in the transfer
functions when a reading is taken from above and below the value to be measured. In
case of control valves for same actuator signal different stem travel (hence valve
coefficients) are obtained depending upon the direction of change in the signal. The
maximum error in stem travel (or valve coefficient) expressed in % for same actuator
pressure while opening and closing the valve is indicated as hysteresis.
3.
EXPERIMENTAL PROCEDURE:
1. Start the set-up for Equal % Control Valve.
2. Open Pneumatic Line for the Control Valve.
3. Open the Control Valve fully. As the Control Valve is Air to Close so pressure in
diaphragm should be 0 psig.
4. Adjust the Rotameter for 500 LPH flow by regulating the valve provided at the
inlet line of the Control Valve.
5. Wait for 5 minutes to steady the flow.
6. Record the Manometer reading in mm of water.
7. Record the Rotameter reading.
8. Now slowly increase the air pressure by regulator upto 3 psig.
9. Wait for 5 minutes to steady the flow and note down the reading of Rotameter,
Manometer and Pressure in psig.
10. Repeat the procedure and take the readings at +3 psig till the valve is fully closed
(Pressure upto 15 psig).
11. Now increase the pressure upto 20 psig and start decreasing the pressure
gradually upto 15 psig.
12.
12
13.
14.
15.
Repeat the procedure and take the readings at 3 psig till the valve is fully
opened (Pressure upto 0 psig).
16.
Calculate valve flow coefficient for actuator pressure for every reading.
17.
The ratio of
4.
Increasing Pressure
Decreasing Pressure
(psig)
P, mm Q, LPH
P,mm of Q, LPH
of H20
H20
3
6
9
12
15
CALCULATIONS:
C v = 1.16 Q
G
= ----------------P
Hysteresis % =
5.
NOMENCLATURE:
Cv
13
6.
REFERENCES:
1. Donald R. Coughanowr, Process System Analysis and Control, 2nd ed.,
McGraw Hill, NY, 1991, Page 315.
14
EXPERIMENT NO. 5:
STUDY OF RANGEABILITY
1. AIM:
To study the rangeability of equal % valve.
2. THEORY:
Equal % valve has a characteristic such that flow changes by a constant % of its
instantaneous value for given % change in stem position. Generally this type of valve
does not shut off the flow completely in its limit of stem travel. The rangeability (R) is
defined as the ratio of maximum to minimum controllable flow.
R=
Fmax
Fmin
Where F max is the flow when the valve stem is at nearly extreme open position for
maximum controllable flow. Fmin is the flow when valve stem is at nearly extreme
closed position for minimum controllable flow.
Fmax, Fmin represents flow rates measured at constant pressure drop across control valve.
Hence rangeability R also can be defined as ration of Cv max to Cv min.
For Equal % valve flow has an exponential characteristics of rangeability, F = R m-1.
R is the rangeability of the valve and m is its fractional stem position.
3. EXPERIMENTAL PROCEDURE:
1. Start up the setup for equal % control valve.
2. Adjust the Rotameter valve and set 500 LPH flow.
3. Set actuator air pressure to 3 psig.
4. Note down the flow rate and pressure at inlet of control valve.
5. Set actuator air pressure to 15 psig
6. Note down the flow rate and pressure at inlet of control valve.
15
4.
P, mm
(psig)
of H2O
F,LPH
Cv
Remarks
Nearly 3
max
Nearly 15
min
CALCULATIONS:
R=
C v max
= --------------C v min
R=
Fmax
= -------------Fmin
[Repeat the experiment by keeping constant pressure drop across the control valve and
note the flow rates.
5. NOMENCLATURE:
R
Rangeability
Cv
Fmax =
Fmin =
6. REFERENCES:
1. Donald R. Coughanowr, Process System Analysis and Control, 2nd ed., McGraw
Hill, NY, 1991, Page 309.
16