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SC-GCM-62 CM Issue 2 © Copyright 2005 Spirax-Sarco Limited
Module 7.2
Typical Self-acting Temperature
Control Valves and Systems
Flow
Figure 7.2.2 illustrates a design which is adjusted at the actuator end of the system. It is worth
noting that this system is limited to 1" (DN25) temperature control valves. This configuration is
useful where the control valve position is more accessible than the sensor position.
Flow
Sensor
Figure 7.2.3 depicts a third configuration which is similar to the one in Figure 7.2.1 but where
the adjustment is located between the sensor and the temperature control valve actuation. This
type of system is referred to as remote adjustment, and is helpful when either the control valve
or the sensor, or both, are likely to be inaccessible once the control valve has been installed.
Temperature control valve
Flow
Capillaries
It should be noted that capillaries of 10 metres or more in length may slightly affect the accuracy
of the control. This is because a larger amount of capillary fluid is subjected to ambient
temperature. When the ambient temperature changes a lot, it can affect the temperature setting.
If long lengths of capillary are run outside, it is recommended they are lagged to minimise this effect.
Pockets
Pockets (sometimes called thermowells) can be fitted into pipework or vessels. These enable the
sensor to be removed easily from the controlled medium without the need to drain the system.
Pockets will tend to slow the response of the system and, where the heat load can change
quickly, should be filled with an appropriate conducting medium to increase the heat transfer to
the sensor.
Pockets fitted to systems which have relatively steady or slow changing load conditions do not
usually need a conducting medium. Pockets are available in mild steel, copper, brass or stainless
steel. Long pockets of up to 1 metre in length are available for special applications and in glass
for corrosive applications. However, these longer pockets are only suitable for use where the
adjustment head is not fitted at the sensor end.
Temperature
control valve
Storage
Calorifier
Flow
Adjustable
temperature
sensor
Fig. 7.2.4 High limit cut-out unit with fail-safe control system
The system is driven by a self-acting control system, which releases a compressed spring in the
high limit cut-out unit and snaps the isolating valve shut if the pre-set high limit temperature is
exceeded.
The fail-safe actuator unit does not drive the control valve directly, but a shuttle mechanism in
the high limit cut-out unit instead. When the temperature is below the set point, the mechanism
lies dormant. A certain amount of shuttle travel is allowed for in either direction, to avoid spurious
activation of the system.
However, when the system temperature rises above the adjustable high limit temperature, the
actuator drives the shuttle, displacing the trigger, which then releases the spring in the high limit
cut-out unit. This causes the control valve to snap shut. Once the fault has been rectified, and
after the system has cooled below the set temperature, the high limit cut-out can be manually
reset, using a small lever. The system can also be connected to an alarm system via an optional
microswitch.
The high limit system also has a fail-safe facility. If the capillary is damaged and loses fluid, a
spring beyond the shuttle is released, pushing it the other way. This will also activate the cut-out
and shut the control valve.
The trigger temperature can be adjusted between 0°C and 100°C.
The fail-safe actuator unit shown in Figure 7.2.5 is only suitable for use with a high limit cut-out
unit. The systems shown in Figures 7.2.1, 7.2.2 and 7.2.3 can also be used with the cut-out unit
but they will not fail-safe. Figure 7.2.5 shows the high limit cut-out unit attached to a separate
valve to the temperature control valve. This is preferable because the high limit valve remains
fully open during normal operation and is less likely to harbour dirt under the valve seat. The
high limit valve should be line size to reduce pressure drop in normal use, and should be fitted
upstream of the self-acting (or other) control valve and as close to it as possible.
Separator Temperature
control valve
Steam
Flow
High limit High limit
protection temperature
sensor
High limit Fail-
cut-out unit safe
actuator
unit
Normal
temperature
Condensate sensor
Hot water
storage calorifier
Return
Cold water
make-up
Condensate
Fig. 7.2.5 Typical arrangement showing a high limit cut-out on DHWS heat exchanger
For heating applications, the high limit valve must be fitted in series with the temperature control
valve, as shown in Figure 7.2.5. However, in cooling applications, the temperature control valve
and high limit valve will both be of the normally-open type and must be fitted in parallel with
each other, not in series.
The following valves can be used with the high limit system:
o Two-port valves, normally open for heating systems.
o Two-port valves, normally closed for cooling systems.
o Three-port valves.
Valves having a ball shaped plug cannot be used with the cut-out unit. This is because the closing
operation could drive the ball into the seat and damage the valve.
Also, a double seated valve should not be used with this system because it does not have tight
shut-off.
Reverse acting
higher capacity
valve
Normally
open Normally open
medium low capacity
capacity valve
valve
Reverse acting
medium capacity
valve
Bellows
balanced
valve
Double seated
Double reverse acting
seated valve
valve
Spacer
Fig. 7.2.7
Twin sensor
adaptor
Fig. 7.2.8
Manual actuator
Manual
actuator
Industrial
o Metal plating - tank heating.
o Tank farms - heating.
o Refineries.
o Industrial washing.
o Steam and condensate systems.
o Laundries.
Non-storage calorifiers
o 2-port temperature control and overheat protection, (steam or water).
o 3-port temperature control and overheat protection (water only).
o 2-port time / temperature control (steam only).
Storage calorifiers
o 2-port temperature or time / temperature control and overheat protection (steam or water).
o 3-port control and overheat protection (water only).
Heating systems
o Basic mixing valve and compensating control.
o Zoned compensating controls.
o Basic compensator plus internal zone controls.
o Control of overhead radiant strip or radiant panels.
Process control
o Acid pickling tank.
o Plating vat.
o Process liquor boiling tank.
o Brewing plant detergent tank.
o Drying equipment, for example, laundry cabinet or wool hank dryer, chemical plant drying
stove for powder and cake, tannery plant drying oven.
o Continuous or batch process reaction pan.
o Food industry jacketed pan.
Cooling applications
o Diesel engine cooling.
o Rotary vane compressor oil cooler control.
o Hydraulic and lubricating oil coolers.
o Cooling control on cold water to single-stage compressor.
o Closed circuit compressor cooling control.
o Air aftercooler control.
o Air cooler battery control.
o Jacketed vessel water cooling control.
o Degreaser cooling water control.
Special applications
o Control for reducing fireside corrosion and thermal stress in LTHW boilers.
o Hot water cylinder control.
o Temperature limiting.
Questions
Answers
1: d, 2: b, 3: b, 4: c, 5: c, 6: c