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CONTROL VALVE

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

5. Precaution & Maintenance Instructions

. 3

6. Troubleshooting

. 3

Experiment No. 1: Study the Control valve Flow Co-efficient (Cv)


1. Aim

. 4

2. Theory

. 4

3. Experimental Procedure

. 5

4. Observation & Calculation

. 5

5. Nomenclature

. 6

6. References

. 6

Experiment No. 2: Study the Inherent Characteristics of Control Valve


1. Aim

. 7

2. Theory

. 7

3. Experimental Procedure

. 8

4. Observation & Calculation

. 8

5. Nomenclature

. 9

6. References

. 9

Control Valve Characteristics (Two Valves)

Experiment No. 3: Study the Installed Characteristics of Control Valve


1. Aim

. 10

2. Theory

. 10

3. Experimental Procedure

. 10

4. Observation & Calculation

. 11

5. Nomenclature

. 11

6. References

. 11

Experiment No. 4: Study the Hysteresis of Control valve


1. Aim

. 12

2. Theory

. 12

3. Experimental Procedure

. 12

4. Observation & Calculation

. 13

5. Nomenclature

. 13

6. References

. 13

Experiment No. 5: Study the Rangeability of Control Valve


1. Aim

. 15

2. Theory

. 15

3. Experimental Procedure

. 15

4. Observation & Calculation

. 16

5. Nomenclature

. 16

6. References

. 16

Control Valve Characteristics (Two Valves)

CONTROL VALVE CHARACTERISTICS


(TWO VALVES)

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.

TYPES OF CONTROL VALVE:


Valve is essentially a variable orifice. Control valve is a valve with a pneumatic,
hydraulic, electric (excluding solenoids) or other externally powered actuator that
automatically, fully or partially opens or closes the valve to a position dictated by
signals transmitted from controlling instruments. Control valves are used primarily to
throttle energy in a fluid system and not for shutoff purpose. Depending upon the valve
plug design the control valves can be divided in three categories as under:
i) Equal % Type.

Control Valve Characteristics (Two Valves)

Flow changes by a constant percentage of its instantaneous value for each unit of
valve lift.
Q = be ay
Q

flow at constant pressure drop

valve opening

base of natural logarithms

a and b=

constants

Constants a and b can be evaluated to give more convenient from

log R
x y
Q = Qo e
y max
Qo

Flow at constant drop at zero stroke

Flow range of valve, maximum to minimum at constant drop.

ymax

maximum rated valve opening

ii) Linear Type.


Flow is directly proportional to valve lift.
F
m
=
Fmax mmax
Q=ky

Flow at constant pressure drop

Valve opening

Constant

ii) Quick Opening Type (On/Off Type).


Flow increases rapidly with initial travel reaching near its maximum at a low lift. It
is generally not defined mathematically.

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.

Control Valve Characteristics (Two Valves)

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.

Compressed Air Supply: 1 CMH at 2 Bar


Water Supply
Drain

5.

PRECAUTIONS & MAINTENANCE INSTRUCTIONS:


1. Never run the apparatus if power supply is less than 180 volts & 230 volts.
2. If apparatus will not in use for more than one month, drain the apparatus
completely & fill pump with cutting oil.
3. To prevent clogging of moving parts, run pump at least once in a fortnight.
4. Always use clean water.
5. Always keep apparatus free from dust.

6.

TROUBLESHOOTING:
1.

If pump gets jam, open the back cover of pump & rotate the shaft manually.

Control Valve Characteristics (Two Valves)

EXPERIMENT NO. 1:

STUDY OF CONTROL VALVE FLOW CO-EFFICIENT (Cv)

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.

CONTROL VALVE FLOW CO-EFFICIENT:


A correction factor is known as valve coefficient and is measured as the number of
USGPM (US Gallon per Minute) that flows through a fully open valve with a
Pressure Drop of 1 psig.
1 US Gallon = 3.785 Liters.
In SI Units the formulae for calculating Cv is:

Q = Kv

v
G

Where: Q = flow rate, m3/hr


Pv

Pr. drop across valve, kgf/cm2

Relation between KV & Cv is:

Control Valve Characteristics (Two Valves)

KV = 0.856Cv

G
P

C v = 1.16 Q
Where:
Q

Discharge of Fluid in m3/h

Pressure Drop in Bar.

Specific Gravity of Fluid

To convert P in mm of H2O in Bar = P mm of H2O/(10.33X103) Bar.

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.

OBSERVATION & CALCULATION:


OBSERVATION TABLE:
S.No.

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.

Control Valve Characteristics (Two Valves)

5.

6.

NOMENCLATURE:
Cv

Flow coefficient of control valve

Specific gravity of fluid

Pressure drop, Bar

Flow rate, LPH

REFERENCES:
1. Donald R. Coughanowr, Process System Analysis and Control, 2nd ed.,
McGraw Hill, NY, 1991, Page 305-309.

Control Valve Characteristics (Two Valves)

EXPERIMENT NO. 2:

STUDY OF INHERENT CHARACTERISTIC OF


LINEAR CONTROL VALVE
1. AIM:
To study the Inherent Characteristic of Linear Control Valve and to determine the flow
coefficient Cv of control valve

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

Control Valve Characteristics (Two Valves)

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.

OBSERVATION & CALCULATION:


OBSERVATION TABLE:

Stem lift in mm

14

12

10

Q, LPH
P,mmH2O

CALCULATIONS:
C v = 1.16 Q

G
= ---------------------P

Control Valve Characteristics (Two Valves)

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

Flow coefficient of control valve

Specific gravity of fluid

Pressure drop, Bar

Flow rate, LPH

REFERENCES:
1. Peter Harriott, Process Control, 19th ed., McGraw Hill, NY, 2000, Page 194198.

Control Valve Characteristics (Two Valves)

EXPERIMENT NO.3:

STUDY OF INSTALLED CHARACTERISTIC OF


CONTROL VALVE
1. AIM:
To study Installed Characteristics of Control valve and to determine the flow coefficient
Cv of control valve

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.

4. OBSERVATION & CALCULATION:


OBSERVATION TABLE:
As valve is air to close lift is measured from 14 to 0 mm
Stem Lift in mm

14

12

10

Q, LPH
P, mm of H2O

CALCULATIONS:
C v = 1.16 Q

G
= ---------------------P

Installed characteristics of the linear valve slightly approaches to the characteristic of


quick opening valve and that of equal % valve approaches to linear characteristic
because of the pipe friction and other resistance to the flow.

5.

6.

NOMENCLATURE:
Cv

Flow coefficient of control valve

Specific gravity of fluid

Pressure drop, Bar

Flow rate, LPH

REFERENCES:
1. Donald R. Coughanowr, Process System Analysis and Control, 2nd ed.,
McGraw Hill, NY, 1991, Page 309-310.

Control Valve Characteristics (Two Valves)

11

EXPERIMENT NO. 4:

STUDY OF HYSTERESIS OF CONTROL VALVE

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.

Wait for 5 minutes to steady the flow.

Control Valve Characteristics (Two Valves)

12

13.

Record the Manometer reading in mm of water.

14.

Record the Rotameter reading.

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.

Plot the graph of actuator pressure versus flow coefficient.

The ratio of

maximum difference between flow coefficients at same actuator pressure to that


of maximum flow coefficient is termed as hysteresis.
18.

4.

Repeat the experiment for the other two valves.

OBSERVATION & CALCULATION:


OBSERVATION TABLE:
Pressure

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

C V at decreasing pressure C V at increasing pressure


x 100 = -------Maximum C V
Repeat the experiment for linear valve. As the Control Valve is Air to Open so keep

Hysteresis % =

in mind this parameter during conducting the experiment.

5.

NOMENCLATURE:
Cv

Flow coefficient of control valve

Specific gravity of fluid

Pressure drop, mm of H2O

Flow rate, LPH

Control Valve Characteristics (Two Valves)

13

6.

REFERENCES:
1. Donald R. Coughanowr, Process System Analysis and Control, 2nd ed.,
McGraw Hill, NY, 1991, Page 315.

Control Valve Characteristics (Two Valves)

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.

Control Valve Characteristics (Two Valves)

15

4.

OBSERVATION & CALCULATION:


OBSERVATION TABLE:
Pressure

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

Flow coefficient of control valve

Fmax =

Maximum controllable flow rate

Fmin =

Minimum controllable flow rate

Pressure drop, mm of H2O

6. REFERENCES:
1. Donald R. Coughanowr, Process System Analysis and Control, 2nd ed., McGraw
Hill, NY, 1991, Page 309.

Control Valve Characteristics (Two Valves)

16

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