Process Valves

Process Valves and Accessories
Instrument Unit
PAKARAB FERTILIZERS LIMITED MULTAN
GEN-03 (Rev 0)
Prepared by : Zia ul Qammar
Reviewed by : Ali Raza Soomro
Approved by : Pervaiz Iqbal
Contents
1. Introduction to Control Valve
1.1 What is Control Valve?

1.2 Control Valve Symbols
1.3 Control Valve Terminology
2. Types of Control Valve
2.1 Linear Motion

2.1.1 Globe Valve
2.1.2 Single/Double Seated Valve
2.1.3 Angle Valve
2.2.4 3 Way Valve
2.2.5 Gate Valve
2.2 Rotary Motion
2.2.1 Butterfly Valve

2.2.2 V- Notch Ball Control Valve
2.1.3 Eccentric- Disk Control Valve Bodies
2.1.4 Eccentric- Plug Control Valve Bodies
2.2.5 Ball Valve
2.2.6 Rotary Plug Valve
Process Valves and Accessories | GEN-03 (Rev 0)
3. Control Valve Parts
3.1 Actuator
3.1.1 Diaphragm Type Actuator

3.1.2 Parts of Diaphragm Actuator
3.1.3 Piston Actuators
3.1.4 Parts of Piston Actuator
3.1.5 Electric Actuator
3.2 Body
3.2.1 Parts of Valve Body
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3.2.2 Bonnet
3.2.3 Extension Bonnets
3.2.4 Bellows Seal Bonnets
3.2.5 Flow Characteristic
3.2.6 Balanced –Plug Cage Style Valve Bodies
3.2.7 Different shapes of plugs
3.2.8 Types of Actuator/Plug with respect to Actions
3.3 Cage
3.4 Packing Box
4. Control Valve Accessories
4.1 Positioner
4.2 Limit Switches
4.3 Solenoid Valve
4.4 Air Regulator
4.5 Lock Up Systems
4.6 Fail Safe Systems for Piston Actuators
4.7 Electro Pneumatic Transducers
4.8 Electro Pneumatic Valve Positioners
5. Troubleshooting
5.1 Table for Troubleshooting

5.2 Packing Maintenance
5.3 Lapping the Seats
5.4 Replacing the Actuator Diaphragm

5.5 Replacing threaded- in Seat rings
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1. Introduction to Control valve
Learning objectives:
 To have a general introduction of Control Valve
 To understand how control valve played the roll in industries
 To remember control valves symbols used in instruments documents
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1.1- What Is A Control Valve?
Process plants consist of hundreds, or even thousands, of control loops all networked
together to produce a product to be offered for sale. Each of these control loops is
designed to keep some important process variable such as pressure, flow, level,
temperature, etc. within a required operating range to ensure the quality of the end
product. Each of these loops receives and internally creates disturbances that
detrimentally affect the process variable, and interaction from other loops in the network
provides disturbances that influence the process Variable.
To reduce the effect of these load disturbances, sensors and transmitters collect
information about the process variable and its relationship to some desired set point. A
controller then processes this information and decides what must be done to get the
process variable back to where it should be after a load disturbance occurs.
When all the measuring, comparing, and calculating are done, some type of final control
element must implement the strategy selected by the controller. The most common final
control element in the process control industries is the 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. Many people who talk about control valves or valves are really referring
to a control valve assembly. 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, and a variety.
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1.2- Valve Symbols
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Control Valve Actuators
1.3- Control Valve Terminology
Flow Coefficient (CV)
A constant (CV) related to the geometry of a valve, for a given travel, that can be
used to establish flow capacity. It is the number of U.S. gallons per minute of 60_F
water that will flow through a valve with a one pound per square inch pressure drop.
Rated Flow Coefficient (CV)

The flow coefficient (CV) of the valve at rated travel.
Rated Travel
The distance of movement of the closure member from the closed position to the
rated full-open position. The rated full-open position is the maximum opening
recommended by the manufacturers.
Flow Characteristic
Relationship between flow through the valve and percent rated travel as the
latter is varied from 0 to 100 percent. This term should always be designated as either
inherent flow characteristic or installed flow characteristic.
Equal Percentage Characteristic

An inherent flow characteristic that, for equal increments of rated travel, will
ideally give equal percentage changes of the flow coefficient (CV)
Quick Opening Characteristic

An inherent flow characteristic in which a maximum flow coefficient is achieved
with minimal closure member travel
Linear Characteristic
An inherent flow characteristic that can be represented by a straight line on a
rectangular plot of flow coefficient (CV) versus rated travel. Therefore equal increments
of travel provide equal increments of flow coefficient, Cv.
Final Control Element

The device that implements the control strategy determined by the output of the
controller. While the final control element can be a damper, a variable speed drive
pump, or an on-off switching de device, the most common final control
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Element in the process control industries is the control valve assembly. The control
valve manipulates a flowing fluid, such as gasses, 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.
Fail-Closed
A condition wherein the valve closure member moves to a closed position when
the actuating energy source fails.
Fail-Open
A condition wherein the valve closure member moves to an open position when
the actuating energy source fails.
Fail-Safe
A characteristic of a valve and its actuator, which upon loss of actuating energy
supply, will cause a valve closure member to be fully closed, fully open, or remain in
the last position, whichever position is defined as necessary to protect the process. Fail-
safe action can involve the use of auxiliary controls connected to the actuator.
Vena Contracta
The portion of a flow stream where fluid velocity is at its maximum and fluid
static pressure and the cross-sectional area are at their minimum. In a control valve, the
vena contracta normally occurs just downstream of the actual physical restriction.
Backlash
The general name given to a form of dead band that results from a temporary
discontinuity between the input and output of a device when the input of the device
changes direction. Slack or looseness of a mechanical connection is a typical example.
Seat Load
The net contact force between the closure member and seat with stated static
conditions. In practice, the selection of an actuator for a given control valve will be
based on how much force is required to overcome static, stem, and dynamic unbalance
With an allowance made for seat load.
Capacity* (Valve)
The rate of flow through a valve under stated conditions
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Trim
The internal components of a valve that modulate the flow of the controlled fluid. In
a globe valve body, trim would typically include closure member, seat ring, cage, stem,
and stem pin.
Closure Member Guide

That portion of a closure member that aligns its movement in a cage, seat ring,
bonnet, bottom flange, or any two of these.
Closure Member
The movable part of the valve that is positioned in the flow path to modify the
rate of flow through the valve.
Actuator Assembly
An actuator, including all the pertinent accessories that make it a complete
operating unit.
Accessory
A device that is mounted on the actuator to complement the actuator’s
functioned and makes it a complete operating unit. Examples nclude positioners,
supply pressure regulators, solenoids, and limit switches.
Positioner
A position controller (servomechanism) that is mechanically connected to a
moving part of a final control element or its actuator and that automatically adjusts its
output to the actuator to maintain a desired position in proportion to the input signal

Bellows Seal Bonnet
A bonnet that uses a bellows for sealing against leakage around the closure
member stem
Plug
A term frequently used to refer to the closure member.
Seat
The area of contact between the closure member and its mating surface that
establishes valve shut-off.
Port
The flow control orifice of a control valve.
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Retaining Ring
A split ring that is used to retain a separable flange on a valve body.
Static Unbalance
The net force produced on the valve stem by the fluid pressure acting on the
closure member and stem with the fluid at rest and with stated pressure conditions.
Trim, Soft-Seated
Valve trim with an elastomeric, plastic or other readily deformable material used
either in the closure component or seat ring to provide tight shutoff with minimal
actuator forces.
Effective Area
In a diaphragm actuator, the effective area is that part of the diaphragm area
that is effective in producing a stem force. The effective area of a diaphragm might
change as it is stroked, usually being a maximum at the start and a minimum at the end
Of the travel range. Molded diaphragms have less change in effective area than flat
sheet diaphragms; thus, molded diaphragms are recommended.
Bench Set
The calibration of the actuator spring range of a control valve to account for the
in-service process forces.
.
Clearance Flow
That flow below the minimum controllable flow with the closure member not
seated.
Diaphragm Pressure Span

Difference between the high and low values of the diaphragm pressure range.
This can be stated as an inherent or installed characteristic.
Feedback Signal
The return signal that results from a measurement of the directly controlled
variable. For a control valve with a positioner, the return signal is usually a mechanical
indication of closure member stem position that is fed back into the positioner.
Loading Pressure
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The pressure employed to position a pneumatic actuator. This is the pressure
that actually works on the actuator diaphragm or piston and it can be the instrument
pressure if a valve positioner is not used.
Hunting
An undesirable oscillation of appreciable magnitude, prolonged after external
stimuli disappear. Sometimes called cycling or limit cycle, hunting is evidence of
operation at or near the stability limit. In control valve applications, hunting would
appear as an oscillation in the loading pressure to the actuator caused by instability in
the control system or the valve positioner.
Sensitivity
The ratio of the change in output magnitude to the change of the input that
causes it after the steady-state has been reached.
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2. Types of Control valve
To understand the following types of control valves
 Linear Motion
 Globe Valve
 Single/Double Seated Valve
 Angle Valve
 3 Way Valve
 Gate Valve
 Rotary Motion
 Butterfly Valve
 Ball Valve
 Plug Valve
Types of Control Valve

There are two basic types of control valves linear motion and rotary motion control
valves. Linear motion control valves commonly have globe, gate, diaphragm, angle, or
3way –type closures. Rotary motion valves have ball, butterfly, or plug closures.
2.1- Linear Motion Control Valve

Linear motion control valves resemble the globe valve shown in following Fig.2.1 in
that the valve plug is positioned by the stem that slides through a packing gland.

Typically, linear motion control valves may be single seated globe, double seated globe
valves, or gate valves. Each of the various types of valve plugs has advantages and
disadvantages mentioned in table -2.2
linear mot ion control valves have many different body styles. The most common takes
the form of a globe, these valves may be either single seated or double seated .single
seated valves are commonly employed in situations where tight shut off is required or
for valves with sizes of 1 inch or smaller.
Double seated valves generally experience leakage through the valve that is somewhat
greater than in single seated valves. This is because it is virtually impossible to close the
two ports simultaneously, especially when thermal expansion and other factors are
considered. The advantage of double seated bodies, however, is that the hydrostatic
effect of the fluid pressure acting on each of the two seats will tend to cancel each other
out ,and much less actuator force is necessary.
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Linear stem motion valves are also used in three way valve bodies where the control
valve may used to divert a stream or to combine streams. Linear stem motion valves are
also commonly encountered in angle valve situations. In such cases, the valve body is
typically single seated. In addition, linear stem travel valves are built in Y-style bodies,
in split body styles, and in cage styles, Cage valves usually are designed soothe valve
trim can be easily removed to facilitate maintenance and replacement, if necessary.
Linear stem motion valves are also used in sliding gate valve application and in a
number of similar, special applications.
Fig.2.1 A typical sliding stems Control Valve with a pneumatic Actuator
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Table - 2.2 Summaries of Features for Selected Control Valve Bodies
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2.2- Rotary Motion Control Valve
Rotary shaft valves have enjoyed a substantial increase in usage in recent years. Their
advantages are low weight, simplicity of design, relatively high flow rates, more
reliable and friction free packing, and relatively low initial cost. They cannot usually be
used in sizes below 1 inch.
The most common rotary shaft control valve is the butterfly valve, which is illustrated
in Fig.2.12 Butterfly valves are used in sizes from 2 inches to 36 inches, or larger. They
are often used in applications that involve large flows at high static pressures but have
limited pressure drop availability. Properly selected, the butterfly valve offers the
advantages of low cost. Lightness of weight, simplicity, and space saving size. It also
exhibits good flow control characteristics.
One type of rotary or rotating shaft control valve that is particularly useful is the
eccentric cylindrical plug valve. It is actually a modification of the plug cock widely
used for shutoff service. Its relative capacity is high and its cost is low. It is especially
useful on services involving corrosive fluids, viscous liquids, or suspended solids.
Ball valves are a special class of rotary valves .There is two distinctly different types of
ball control valves. One involves a ball (a complete sphere) that has a waterway through
it. This is generally referred to as the full ball type. The second type is developed along
the lines of the concentric plug valve and utilizes a hallowed out spherical segment, or
partial ball, that is supported by shafts. Advantages of ball valves are low weight,
simple design, high relative CV, more reliable, friction frees packing.
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2.1.1- Globe Valves
Single Seated Valve (Single-port Valve Bodies)
Fig.2.3 Single SEATED Globe Valve
 Single port is the most common valve body style and is simple in construction.
 Single-port valves are available in various forms, such as globe, angle, bar stock,
forged, and split constructions.
 Generally single-port valves are specified for applications with stringent shutoff
requirements. They use Metal-to-metal seating surfaces or soft-seating with PTFE

or other composition materials forming the seal. Single-port valves can handle
most service requirements.
 Although most popular in the smaller sizes, single-port valves can often be used
in 4-inch to 8-inch sizes with high-thrust actuators.
 Single-seated valves usually have a top guided construction it also allows a
somewhat higher flow capacity than top and bottom guided valves.
 Because high-pressure fluid is normally loading the entire area of the port, the
unbalance force created must be considered in selecting actuators and plug for
single-port control valve bodies. High pressure globe style control valve body
and plug shown in Fig.2.4
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Fig. 2.4 High Pressure Globe-Style Control Valve Body and Plug
 Many modern single-seated valve bodies use cage or retainer style construction
to retain the seat ring cage, provide valve-plug guiding, and provide a means for
establishing particular valve flow characteristics. Retainer-style trim also offers
ease of maintenance with flow characteristics altered by changing the plug.
 Cage or retainer-style single seated valve bodies can also be easily modified by
change of trim parts to provide reduced-capacity flow, noise attenuation, or
reduction or elimination of cavitations.
2.1.2- Double Seated Valve (Double-Port Valve Bodies)
 A double-seated value is generally top and bottom guided.

 Leakage figure approaches 0.5% of the rated CV.
 It is nearly impossible to close the two ports simultaneously
 Double seated valves generally experience leakage through the valve that is
somewhat greater than in single seated valves. This is because it is virtually
impossible to close the two ports simultaneously, especially when thermal
expansion and other factors are considered. Double seated reverse acting plug
shown in Fig. 2.5
 Dynamic force on plug tends to be balanced as flow tends to open one port and
close the other.
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 Reduced dynamic forces acting on plug might permit choosing a smaller actuator
than would be necessary for a single-ported valve body with similar capacity.
Fig. 2.5 Reverse-Acting Double-Ported Globe-Style Valve Body

 Bodies are usually furnished only in the larger sizes—4-inch or larger.
 Bodies normally have higher capacity than single-ported valves of the same line
size.
 Many double-ported bodies reverse, so the valve plug can be installed as either
push-down-to-open or push-down-to-close (figure).
 Metal-to-metal seating usually provides only Class II shutoff capability, although
Class III capability is also possible.
 Port-guided valve plugs are often used for on-off or low-pressure throttling
service. Top-and-bottom guided valve plugs furnish stable operation for severe
service conditions.
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 The control valve body shown in figure is assembled for push-down to- open
valve plug action. The valve plug is essentially balanced and a relatively small
amount of actuator force is required to operate the valve. Double ported designs
are typically used in refineries on highly viscous fluids or where there is a
concern about dirt, contaminants, or process deposits on the trim.
2.1.3- Angle Valve

Fig.2.6 Angle Valve
 Angle valves are nearly always single ported (figure 2.6). They are commonly
used for high pressure drop service and heater drain service and in piping
schemes where space is at a premium and the valve can also serve as an elbow.
The valve shown has cage-style construction. Others might have screwed-in seat

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rings, expanded outlet connections, restricted trim, and outlet liners for
reduction of erosion damage.
 Normal flow direction is most often up through the seat ring. Angle valves are
nearly always single as shown in Fig. 2.7
Fig. 2.7 in let Port of Angle Valve
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2.1.4- 3-Way Valve
 Three pipeline connections provide general converging (flow-mixing) or

diverging (flow-splitting) service.
 Best designs use cage-style trim for positive valve plug guiding and ease of
maintenance.
 Variations include trim materials selected for high temperature service. Standard
end connections (flanged, screwed, butt weld, etc.) can be specified to mate with
most any piping scheme.
 Actuator selection demands careful consideration, particularly for constructions
with unbalanced valve plug.
Fig. 2.8 Three Way Valve
 Balanced valve plug style three-way valve body is shown with cylindrical valve
plug in the down position (figure 2.8). This position opens the bottom common
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port to the right-hand port and shuts off the left-hand port. The construction can
be used for throttling mid-travel position control of either converging or
diverging fluids.
2.1.5- Gate Valve

Gate valves are used when a straight-line flow of fluid and minimum
restriction is desired. Gate valves are so named because the part that either stops or
allows flow through the valve acts somewhat like the opening or closing of a gate and is
called, appropriately, the gate. The gate is usually wedge shaped. When the valve is
wide open, the gate is fully drawn up into the valve, leaving an opening for flow
through the valve the same size as the pipe in which the valve is installed. Therefore,
there is little pressure drop or flow restriction through the valve.
Gate valves are not suitable for throttling purposes since the control of flow would be
difficult due to valve design and since the flow of fluid slapping against a partially open
gate can cause extensive damage to the valve. Except as specifically authorized, gate
valves should not be used for throttling
Fig. 2.11a Fig. 2.11b
Gate valves are classified as either RISINGSTEM or NONRISING-STEM valves.

On the non rising-stem gate valve shown in figure 2.11b the stem is threaded on the
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lower end into the gate. As the hand wheel on the stem is rotated, the gate travels up or
down the stem on the threads, while the stem remains vertically stationary. This type of
valve almost always has a pointer-type indicator threaded onto the upper end of the
stem to indicate valve position.
The rising-stem gate valve, shown in figure 2.11a has the stem attached to the gate; the
gate and stem rise and lower together as the valve is operated.
Gate valves used in steam systems have flexible gates. The reason for using a flexible
gate is to prevent binding of the gate within the valve when the valve is in the closed
position. When steam lines are heated, they will expand, causing some distortion of
valve bodies. If a solid gate fits snugly between the seat of a valve in a cold steam
system, when the system is heated and pipes elongate, the seats will compress against
the gate, wedging the gate between them and clamping the valve shut. This problem is
overcome by use of a flexible gate (two circular plates attached to each other with a
flexible hub in the middle). This design allows the gate to flex as the valve seat
compresses it, thereby preventing clamping.
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Rotary Valve
2.2.1- Butterfly Valve Bodies
 Bodies require minimum space for installation (figure 2.12).
 They provide high capacity with low pressure loss through the valves.
Fig.2.12 Butterfly Control Valve Body

 Butterfly valve bodies offer economy, particularly in larger sizes and in terms of
flow capacity per investment dollar.
 Conventional contoured disks provide throttling control for up to 60-degree disk
rotation. Patented, dynamically streamlined disks suit applications requiring 90-
degree disk rotation.
 Bodies mate with standard raised-face pipeline flanges.
 Butterfly valve bodies might require high-output or large actuators if the valve is
big or the pressure drop is high, because operating torques might be quite large.
 Units are available for service in nuclear power plant applications with very
stringent leakage requirements.

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 Standard liner can provide good shutoff and corrosion protection with nitrile or
PTFE liner.
 Standard butterfly valves are available in sizes through 72-inch for miscellaneous
control valve applications. Smaller sizes can use versions of traditional
diaphragm or piston pneumatic actuators, including the modern rotary actuator
styles. Larger sizes might require high-output electric or long-stroke pneumatic
cylinder actuators. Butterfly valves exhibit an approximately equal percentage
flow characteristic. They can be used for throttling service or for on-off control.
Soft-seat construction can be obtained by using a liner or by including an
adjustable soft ring in the body or on the face of the disk.
2.2.2- V-Notch Ball Control Valve

 This construction is similar to a conventional ball valve, but with patented,
contoured V-notch in the ball (figure 2.13). The V-notch produces an equal-
percentage flow characteristic. These control valves have good range ability,
control, and shutoff capability. The paper industry, chemical plants, sewage
treatment plants, the power industry, and petroleum refineries use such valve
bodies.
 Straight-through flow design produces little pressure drop.
 V-notch ball control valve bodies are suited to control of erosive or viscous
fluids, paper stock, or other slurries containing entrained solids or fibers.
 They use standard diaphragm or piston rotary actuators.
 Ball remains in contact with seal during rotation, which produces a shearing
effect as the ball closes and minimizes clogging
 Bodies are available with either heavy-duty or PTFE-filled composition ball seal
ring to provide excellent range ability in excess of 300:1.
 V-notch ball control valve bodies are available in flangeless or flanged body end
connections. Both flanged and flangeless valves mate with Class 150, 300, or 600
flanges or DIN flanges
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Figure .2.13 Rotary-Shaft Control Valve with V-Notch Ball
2.2.3- Eccentric-Disk Control Valve Bodies
Figure .2.14 Eccentric-Disk Rotary-Shaft Control Valve
 Bodies offer effective throttling control.

 Eccentric-disk control valve bodies provide linear flow characteristic through 90
degrees of disk rotation (figure 2.14).
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 Eccentric mounting of disk pulls it away from seal after it begins to open,
minimizing seal wear.
 Eccentric-disk control valve bodies are available in sizes through 24-inch
compatible with standard ASME flanges.
 They use standard pneumatic diaphragm or piston rotary actuators.

 Standard flow direction is dependent on seal design; reverse flow results in
reduced capacity. Eccentric disk rotary shaft control valves are intended for
general service applications not requiring precision throttling control. They are
frequently applied in applications requiring large sizes and high temperatures
due to their lower cost relative to other styles of control valves. The control range
for this style of valve is approximately one third as large as a ball or globe style
valves. Consequently, additional care is required in sizing and applying this style
of valve to eliminate control problems associated with process load changes.
They work quite well for constant process load applications.

2.2.4- Eccentric-Plug Control Valve Bodies

 Valve assembly combats erosion. The rugged body and trim design handle
temperatures to 800_F (427_C) and shutoff pressure drops to 1500 psi (103 bars).
Figure 2.15. Sectional of Eccentric- Plug Control Valve Body W4170/IL
 Path of eccentric plug minimizes contact with the seat ring when opening,
reducing seat wear and friction, prolonging seat life, and improving throttling
performance (figure 2.15).
 Self-centering seat ring and rugged plug allow forward or reverse flow with tight
shutoff in either direction. Plug, seat ring and retainer are available in hardened
materials, including ceramics, for selection of erosion resistance.

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 Designs offering a segmented V-notch ball in place of the plug for higher
capacity requirements are available. This style of rotary control valve suits
erosive, coking and other hard-to-handle fluids, providing either throttling or
on-off operation. The flanged or flangeless valves feature streamlined flow
passages and rugged metal-trim components for dependable service in slurry
applications. Mining, petroleum refining, power, and pulp and paper industries
use these valves.
2.2.5- Ball Valve
Fig. 2.16 Ball Valve
Ball valves are a special class of rotary valves. The use of ball valves for control
purposes has grown rapidly since the early 1960s, although ball valves as such are
much older. The ball valve has historically been used principally as a tight shutoff hand
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valve. In recent years, however, ball valves have been automated for control purposes
and have shown excellent “range ability” and excellent suitability for handing slurries.
There are two distinctly different types of ball control valves. One involves a ball
(a complete sphere) that has a waterway through it. This is generally referred to as the
full ball type. The second type is developed along the lines of the concentric plug valve
and utilizes a hallowed out spherical segment, or partial ball, that is supported by
shafts. These are referred to as “characterized “ball valves and are illustrated in Fig. 2.17
Fig. 2.17 Cross section of a Characterized Ball Control Vale

Both types of ball valves are quarter turn rotary valves. The characterized ball valve is
basically a simple segment of a sphere, which forms a crescent shaped flow path that
produces flows of equal percentage characteristic for high capacity designs and a linear
characteristic for low capacity designs. To obtain other characteristics, the leading edge
of the segment can be contoured, as in the V-notch design and the parabolic port
designs.
In the full ball valve design, the shape of the control orifice goes from circular to
elliptical as the ball is moved from its open to its closed position. This gives an
essentially equal percentage behavior. Changing the shape of the waterway in a full ball
valve is not a practical approach for changing the valves characteristic, and when such a
goal is desired it is often accomplished by using interchangeable cams in the valve
positioner.
Ball valves have the highest flow capacity of any commonly used control valves. They
are useful whenever slurries are involved, they also provide tight shutoff.
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There are two subcategories of ball valves. The through bore of full ball type shown in
Fig. is often used for high pressure drop throttling and on-off application in sizes to
NPS 24 or DN 600 full port designs exhibit high flow capacity and low susceptibility to
wear by erosive streams. However, sluggish flow throttling response in the first 20% of
ball travel makes full bore ball valves unsuitable for throttling applications. Newer
designs in full ball, reduced bore valves provide better response pressure rating up to
class 900 or PN150 are available. As are a variety of end connections and body
materials. Another popular kind of ball valve is the partial ball style fig. this
subcategory is very much like the reduced bore group, except that the edge of the ball
segment has a contoured notch shape for better throttling control and higher range
ability. Intended primarily for modulating service, not merely for on off control. Partial
ball valves are generally higher in overall control performance than full ball products.
They are engineered to eliminate lost motion, which is detrimental to performance. The
use of flexible or movable metallic and Fluor plastic sealing elements allows tight
shutoff and wide temperature and fluid applicability. Their straight through flow
design achieves high capacity, Sizes range through NPS 24 or DN 600. Pressure ratings
go to Class 600 or PN 100 Price is normally lower than that of globe valves
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2.2.6- Rotary Plug Valve
Fig. 2.18 Rotary Plug Valve
One type of rotary or rotating plug control valve that is particularly useful is the
conical plug valve. Its seat is also conical shape made of Teflon material
Widely used for shutoff service. Its relative capacity is high and its cost is low. It is
especially useful on services involving corrosive fluids, viscous liquids, or suspended

solids.
Also illustrated in fig.2.18 is the rotating plug valve. Rotary plug valves also used in
three way valve bodies where the control valve may used to divert a stream or to
combine streams. Generally rotary plug valves are equipped with Rotary pneumatic
actuators it is illustrated in Fig. 2.18a.
Actuators are available to drive rotary action valves, such as ball, butterfly, and rotary
plug valves. The commonest is the piston type, which comprises a central shaft, two
pistons and a central chamber all contained within a casing. The pistons and shaft have
a rack and pinion drive system. In the simplest types, air is fed into the central chamber
Fig. 2.18a. Which forces the pistons outwards.
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. Fig. 2.18a Spring returns rotary pneumatic actuator
The rack and pinion arrangement turns the shaft and, because the latter is coupled to
the valve stem, the valve opens or closes. When the air pressure is relieved, movement
of the shaft in the opposite direction occurs due to the force of the return springs
(Figure 2.18a). It is also possible to obtain double acting versions, which have no return
springs. Air can be fed into either side of the pistons to cause movement in either
direction.
34
35
3. Control Valve Parts
 To remember control valve parts
 To understand how control valve parts assemble
 To understand what functions control valve parts perform
36
Major Parts of a Control Valve
A control valve consists of two major parts Actuator and valve body
3.1- Actuator
A pneumatic, hydraulic, or electrically powered device that supplies force and motion
to open or close a valve. Actuators are the distinguishing elements between valves and
control valves. The actuator industry has evolved to answer a wide variety of process
needs and user desires. Actuators are available with many designs, power sources, and
capabilities. Proper selection involves process knowledge, valve knowledge, and
actuator knowledge. A control valve can perform its function only as well as the
actuator can handle the static and dynamic loads placed on it by the valve. Proper
selection and sizing are, therefore, very important. The actuator represents a significant
portion of the total control valve package price, and careful selection can minimize
costs. The range of actuator types and sizes on the market is so great that it seems the
selection process might be complex. It is not. With a few rules in mind and knowledge
of your fundamental needs, the selection process can be very simple.
The following parameters must be known at the beginning of the selection process.
They are important because they quickly narrow the selection process.
1. Power source availability
2. Failure mode requirements
3. Torque or thrust requirements ( actuator capability )
4. Control functions
5. Economics
6. Size, modular construction, easy maintenance
Pneumatic actuators are available in two main forms:

1. Diaphragm actuators (Figure )
2. Piston actuators (Figure).
3.1.1- Diaphragm Actuator
The most popular and widely used control valve actuator is the pneumatic spring
and diaphragm style (Fig. 3.1). Diaphragm actuators normally operate over the
37
standard signal range of 3 to 15 psig (0.2 to 1 kg/cm2) or 6 to 30 psig (0.4 to 2 kg/cm2).
Therefore they are often suitable for throttling service using instrument signals directly.
Many designs offer either adjustable springs or wide spring selections to allow the
actuator to be tailored to the particular application. Because diaphragm actuators have
few moving parts that might contribute to failure, they are extremely reliable. Should
they ever fail, maintenance is extremely simple. Improved designs include mechanisms
to control the release of spring compression. Reducing the possibility of injury to
personnel during actuator disassembly.
The overwhelming advantage of the spring and diaphragm actuator is the ever –
present provision for fail action. As pressure is loaded on the actuator casing, the
diaphragm moves the valve and compresses the spring. The stored energy in the spring
acts to move the valve back to its original position as pressure is released from the
casing. Should there be a loss of signal pressure to the instrument or the actuator, the
spring can move the valve its initial (fail) position. Actuators are available for either fail
–open (a condition wherein the valve closure member moves to an open position when
the actuating energy source fails) or fail- closed (a condition wherein the valve closure
member moves to a closed position when the actuating energy source fails) action.
The only real drawback to the spring and diaphragm actuator is a relatively limited
capability. Much of the thrust created by diaphragm is taken up by the spring and thus
does not result in output to the valve. Therefore the spring and diaphragm actuator is
seldom used for high force requirements. It is not economical to build and use very
large diaphragm actuators because the size, weight, and cost grow out of proportion to
capability. This limitation is mitigated, however, by the fact that most valves are small
and have low force requirements.
3.1.2- Parts of Diaphragm Actuator

1. Air Connection
2. Diaphragm Casing
3. Diaphragm
4. Diaphragm Metal Plate
38
5. Actuator Spring
6. Actuator Stem
7. Spring Seat
8. Spring Adjuster
9. Stem coupling
10. Yoke
11. Travel Indicator
12. Indicator Scale
13. Stem Lock Nut
14. O ring
15. Vent Port
Direct Actuator
Fig.3.1 Direct Actuator
39
Reverse Actuator
Fig.3.2 Reverse Actuator
Diaphragm Casing: housing, consisting of top and bottom section, used for supporting
a diaphragm and establishing one or two pressure chambers.

Diaphragm: A flexible, pressure responsive element that transmits force to the
diaphragm plate and actuator stem.
Diaphragm Plate: A plate concentric with the diaphragm for transmitting force to the
actuator stem.
Actuator Spring: A spring, or group of springs, enclosed in the yoke or actuator casing
that moves the actuator stem in a direction opposite to that created by diaphragm
pressure.
Actuator Stem: The part that connects the actuator to the valve stem
40
Spring Seat: A plate to hold the spring in position and to provide a flat surface for the
spring adjustor to contact.
Spring Adjustor: A fitting, usually threaded on the actuator stem or into the yoke, to
adjust the spring compression.
Stem Coupling: The device that connects the actuator stem to the valve stem.
Yoke: The structure that rigidly connects the actuator power unit to the Valve.
Travel Indicator: A pointer and scale used to externally show the position of the closure
member typically with units of opening percent of travel or degrees of rotation.
Travel Scale: Travel Scale shows the movement of the closure member from the closed
position to an intermediate or rated full open position.
41
3.1.3- Piston Actuators
Piston actuators, such as those shown in Figs.3.3, 3.4 are the second most popular
control valve actuator style. They are generally more compact and provide higher
torque or force outputs than spring and diaphragm actuators. Piston styles normally
work with supply pressures of between 50 and 150 psig (3.5 and 10.4 bars). Although
piston actuators can be equipped with returns, this construction has limits similar to
those of the spring and diaphragm style.
Piston actuators used throttling service must be equipped with double acting
positioners, which simultaneously load and unload opposite sides of the piston. The
pressure differential created across the piston causes travel toward the lower pressure
side. The positioner senses the motion of the output, and when the required position is
reached, the positioner equalizes the pressure on both sides of the piston.
Fig. 3.3 Double Acting Piston Actuator
42
Double acting piston actuators are used if thrust requirements exceed the capability of
diaphragm actuators. Piston actuators require a higher supply pressure, but they have
benefits such as high stiffness and a more compact.
Fig. 3.4 Spring Based Piston Actuator

Spring fail action is available in this spring based piston actuator. Process pressure
acting on the valve plug can aid fail action, or the actuator can be configured so that the
spring alone closes or opens the valve on failure of operating pressure.
The pneumatic piston actuator is used when a compact high power unit is required.
It is also easily adapted to services where high ambient temperatures are involved.
The main disadvantages of piston actuators are the high supply pressures required.
The requirement for positioners when used for throttling service, and the lack of
inherent failure mode systems. Two types of spring return piston actuator and operate
it much like a spring and diaphragm. These designs use a single acting positioner,
which loads the piston chamber to move the actuator and compress the spring. As
pressure is unloaded, the spring moves the piston back. These designs use large high
output springs, which are capable of overcoming the fluid forces in the valve.
43
The alternative design uses a much smaller spring and relies on valve fluid forces to
help provide the fail action. In normal operation they act like a double acting piston. In
a fail situation the spring initiates movement and is helped by unbalance forces on the
plug.
The only failure mode alternative to springs is pressurized air volume tank
pneumatic trip systems to move the piston actuator to its fail position as shown in
Fig. 3.5 although these systems are quite reliable, they add to overall system complexity,
maintenance difficulty, and cost. Therefore for any failure mode requirement prime
consideration should be given to spring return actuators if they are feasible.
Fig. 3.5 Piston Actuator with Air Volume Tank
Fail action for piston actuators can be accomplished by using pneumatic trip systems. A
switching valve transfers stored pressure from volume tanks to the piston to stroke the
valve and maintain the predetermined failure position.
44
3.1.4- Parts of Piston Actuator
1. Cylinder
2. Actuator stem
3. Piston
4. Piston seal
5. Cylinder closure seal
6. Actuator stem seal
7. Cylinder seal
8. Seal bushing
9. Travel Indicator scale
10. Travel Indicator
11. Yoke
12. Stem connector
Fig. 3.6 Piston Actuator
45
Cylinder: The chamber of a piston actuator in which the piston moves
Actuator Stem: The part that connects the actuator to the valve stem
Piston: A movable pressure responsive element that transmits force to the piston
actuator stem.
Cylinder Closure Seal: The sealing element at the connection of the piston actuator
cylinder to the yoke.
Seal Bushing: Top and bottom bushings that provide a means of sealing
The piston actuator cylinder against leakage. Synthetic rubber O-rings are
Used in the bushings to seal the cylinder, the actuator stem, and the actuator stem
extension.
Travel Indicating Scale: Travel Scale shows the movement of the closure member from
the closed position to an intermediate or rated full open position.
Travel Indicator: A pointer and scale used to externally show the position of the closure
member typically with units of opening percent of travel or degrees of rotation
Yoke: The structure that rigidly connects the actuator power unit to the Valve.
Stem Connector: The device that connects the actuator stem to the valve stem.
. Process Valves and Accessories | GEN-03 (Rev 0)
46
3.1.5- Electric Actuators
Electric actuators can be successfully applied in many situations. Most electric operators
consist of motors and gear trains (Fig. 3.7). They are available in a wide range of torque
outputs, travels, and capabilities. They are suited for remote mounting where no other
power source is available or for use where there are specialized thrust or stiffness
requirements. Electric actuators are economical, compared with pneumatic ones, for
applications in small size ranges only. Larger units operate slowly, weigh considerably
more than pneumatic equivalents, and are more costly. Precision
Throttling versions of electric motor actuators are quite limited in availability. One very
important consideration in choosing an electric actuator is its capability for continuous
closed-loop control. In applications where frequent changes are made in control valve
position, the electric actuator must have a suitable duty cycle.
Fig. 3.7 Technical improvements have made electric actuators practicable for control
purposes. They offer high thrust or torque and high stiffness
While having many disadvantages, the electric actuator will generally provide the
highest output available within a given package size. In addition electric actuators are
47
very stiff, that is, resistant to valve forces, good throttling control of large high-pressure
valves.
3.2- Valve Body

The main pressure boundary of the valve that also provides the pipe connecting ends,
the fluid flow passageway, and supports the seating surfaces and the valve closure
member. Among the most common valve body constructions are: a) single-ported valve
bodies having one port and one valve plug; b) double-ported valve bodies having two
ports and one valve plug; c) two-way valve bodies having two flows connections, one
inlet and one outlet; d) three-way valve bodies having three flow connections, two of
which can be inlets with one outlet (for converging or mixing flows), or one inlet and
two outlets (for diverging or diverting flows). The term valve body, or even just body,
frequently is used in referring to the valve body together with its bonnet assembly and
included trim parts. More properly, this group of components should be called the
valve body assembly.
Fig. 3.8
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Fig.3.9
3.2.1- Parts of Valve Body

1. Stem
2. Packing Flange
3. Yoke Nut
4. Gland packing
5. Packing Follower
6. Bonnet.
7. Bonnet Gasket
8. Spiral wound gasket
9. Cage gasket
10. Valve plug
11. Cage
12. Seat Ring
13. Seat Ring Gasket
49
Fig. 3.10
Trim: The internal components of a valve that modulate the flow of the controlled fluid.
In a globe valve body, trim would typically include closure member, seat ring, cage,
stem, and stem pin, guide bushing, and stuffing box. Trim components provide the
flow control, they are very important to valve performance. Trim materials must
usually have excellent resistance to corrosion by the process fluid. If not, adequate flow
control and mechanical stability will not be maintained. Each component must have
other characteristics, depending on the valve design, process fluid, and application.
Valve Stem: In a linear motion valve, the part that connects the actuator stem with the
closure member.
50
Seat Ring: A part of the valve body assembly that provides a seating surface for the
closure member and can provide part of the flow control orifice.
3.2.2- Bonnet
The portions of the valve that contains the packing box and stems seal and can guide
the stem. It provides the principal opening to the body cavity for assembly of internal
parts or it can be an integral part of the valve body.
It can also provide for the attachment of the actuator to the valve body. Typical bonnets
are threaded, bolted, welded, pressure-seals, or integral with the body. (This term is
often used in referring to the bonnet and its included packing parts. More properly, this
group of component parts should be called the bonnet assembly). On a typical globe-
style control valve body, the bonnet is made of the same material as the valve body or is
an equivalent forged material because it is a pressure-containing member subject to the
same temperature and corrosion effects as the body.
Several styles of valve body-to-bonnet connections are illustrated. The most common is
the bolted flange type shown in figure 3-13 showing a bonnet with an integral flange
and figure 3-11 showing a bonnet with a separable, slip-on flange held in place with a
Split ring.
The bonnet used on the high pressure globe valve body in figure 3-12 is screwed into
the valve body. Figure 3-14 is typical of rotary-shaft control valves where the packing is
housed within the valve body and a bonnet is not used.
Fig. 3-11 Bar Stock Valve Bodies Fig. 3-12. High Pressure Globe l Valve Body
On control valve bodies with cage- or retainer-style trim, the bonnet furnishes loading
force to prevent leakage between the bonnet flange and the valve body and also
between the seat ring and the valve body. The tightening of the body-bonnet bolting
51
compresses a flat sheet gasket to seal the body-bonnet joint, compresses a spiral-wound
gasket on top of the cage, and compresses another flat sheet gasket below the seat ring
to provide the seat ring-body seal. The bonnet also provides alignment for the cage,
which in turn guides the valve plug, to ensure proper valve plug stem alignment with
the packing. As mentioned, the conventional bonnet on a globe-type control valve
houses the packing. The packing is most often retained by a packing follower held in
place by a flange on the yoke boss area of the bonnet (figure 3-13). An alternate packing
retention means is where the packing follower is held in place by a screwed gland
(figure 3-11). This alternate is compact, so it is often used on small control valves
however, the user cannot always be sure of thread engagement. Therefore, caution
should be used in adjusting packing compression when the control valve is in service.
52
Figure 3-13 Typical Bonnet, Flange, and Stud Bolts
Figure 3-14. High-Performance Butterfly Control Valve

53
3.2.3- Extension Bonnets
Extension bonnets are used for either high or low temperature service to protect
valve stem packing from extreme process temperatures. Standard PTFE valve stem
packing is useful for most applications up to 450_F (232_C). However, it is susceptible
to damage at low process temperatures if frost forms on the valve stem. The frost
crystals can cut grooves in the PTFE, forming leakage paths for process fluid along the
stem. Extension bonnets remove the packing box of the bonnet far enough from the
extreme
Temperature of the process that the packing temperature remains within the
recommended range. Extension bonnets are either cast (figure 3.16) or fabricated (figure
3-15). Cast extensions offer better high-temperature service because of greater
Heat. Emissive, which provides better cooling effect. Conversely, smooth
Fig. 3.16 Extension Bonnet
Figure 3-15. Valve Body

With Fabricated Extension Bonnet
54
3.2.4- Bellows Seal Bonnets
Bellows seal bonnets (figure 3.17) are used when no leakage (less than 1x10-6 cc/sec of
helium) along the stem can be tolerated. They are often used when the process fluid is
toxic, volatile, radioactive, or highly expensive.
This special bonnet construction protects both the stem and the valve packing from
contact with the process fluid. Standard or environmental packing box constructions
above the bellows seal unit will prevent catastrophic failure in case of rupture or failure
of the bellows. As with other control valve pressure/ temperature limitations, these
pressure ratings decrease with increasing temperature. Selection of a bellows seal
design should be carefully considered and particular attention should be paid to proper
inspection and maintenance after installation. The bellows material should be carefully
Considered to ensure the maximum cycle life. Two types of bellows seal designs are
Used for control valves. These are mechanically formed and welded leaf bellows (figure
3-18 and figure 3-19 respectively). The welded-leaf design offers a shorter total package
height. Due to its method of manufacture and inherent design, service life may be
limited. The mechanically formed bellows is taller in comparison and is produced
With a more repeatable manufacturing process.
Fig. 3-17. SEAL Fig.3.18 Mechanically Formed Bellows

Bellows Seal Bonnet Fig.3.19 Welded Leaf Bellows
55
Surfaces, such as can be fabricated from stainless steel tubing, and are preferred for cold
service because heat influx is normally the major concern. In either case, extension wall
thickness should be minimized to cut down heat transfer. Stainless steel is usually
preferable to carbon steel because of its lower coefficient of thermal conductivity. On
Cold service applications, insulation can be added around the extension to protect
further against heat influx.
Bottom Flange: A part that closes a valve body opening opposite the bonnet opening. It
can include a guide bushing and/or serve to allow reversal of the valve action.
Bushing: A device that supports and/ or guides moving parts such as valve stems.
Valve Plug: A term frequently interchanged with plug in reference to the closure
member. There are many types of plug with respect to their shapes already discussed in
the last chapter (types of valves)
Here are discussed the plugs with respect to the flow characteristics.
3.2.5- Flow Characteristic

Flow characteristic refers to the pattern in which the flow at constant pressure
drop changes according to valve position. Typical characteristics are quick opening,
linear, and equal percentage. The choice of characteristic has a strong influence on the
stability or controllability of the process, because it represents the change of valve gain
relative to travel.
Most control valves are carefully “characterized “to exhibit a certain flow characteristic
by means of contours on a plug, cage, or ball element. Some valves are available in a

variety of characteristics to suit the application while others offer little or no choice.
To determine the best flow characteristic for a given application quantitatively, a
dynamic analysis of the control loop can be performed. In most cases, however, this is
unnecessary; reference to established rules will suffice. Fig. illustrates typical flow
characteristic curves. The quick opening flow characteristic provides for maximum
Change in flow rate at low valve travels with a fairly linear relationship. Additional
increases in valve travel give sharply reduced changes in flow rate, and when the valve
plug nears the wide open position, the change in flow rate approaches zero. In a control
Valve, the quick opening valve plug is used primarily for on off service, but it is also
suitable for many applications where a linear valve plug would normally be specified.
The linear flow characteristic curve shows that the flow rate is directly
proportional to the valve travel. This proportional relationship produces a characteristic
with a constant slope so that with constant pressure drop, the valve gain will be the
56
same at all flows. The linear valve plug is commonly specified for liquid level control
and for certain flow control applications requiring constant gain.
In the equal percentage flow characteristic, equal increments of valve travel
produce equal percentage changes in the existing flow, the change in flow rate is always
proportion to the flow rate just before the change in valve plug, disk, or ball position is
made, when the valve plug, disk, or ball is near its seat and the flow is small, the change
in flow rate will be small. With a large flow, the change in flow rate will be large. Valves
with an equal percentage flow characteristic are generally used on pressure control
applications and on other applications where a large percentage of the pressure drop is
normally absorbed by the system itself. With only a relatively small percentage
available at the control valve. Valves with an equal percentage characteristic should also
be considered where highly varying pressure drop conditions can be expected.
Quick Opening Plug
Fig.3.20 Quick Opening Plug

o Valve Opening 30 % CV  62
CV  90
o Valve Opening 70 %
57
Linear Plug
Fig.3.21 Linear Plug
Equal Plug

Fig.3.22 Equal % Plug
58
Fig. 3.23
3.2.6- Balanced-Plug Cage-Style Valve Bodies

This popular valve body style, single ported in the sense that only one seat ring is used,
provides the advantages of a balanced valve plug often associated only with double
ported valve bodies (figure 3.15). Cage-style trim provides valve plug guiding, seat ring
Retention, and flow characterization. In addition a sliding piston ring-type seal between
the upper portion of the valve plug and the wall of the cage cylinder virtually
eliminates leakage of the upstream high pressure fluid into the lower pressure
downstream system. Downstream pressure acts on both the top and bottom sides of the
valve plug, thereby nullifying most of the static unbalance force. Reduced unbalance
Permits operation of the valve with smaller actuators than those necessary for
conventional single-ported valve bodies. Interchangeability of trim
Permits choice of several flow characteristics or of noise attenuation or anticavitation
Components. For most available trim designs, the standard direction of flow is in
through the cage openings and down through the seat ring. These are available in
59
various material combinations, sizes through 20-inch, and pressure ratings to Class
2500.
Figure. 3.24 High Capacity Valve Body with Cage-Style Noise Abatement Trim
High Capacity, Cage-Guided Valve Bodies

This adaptation of the cage-guided bodies mentioned above was designed for noise
applications such as high pressure gas reducing stations where sonic gas velocities are
often encountered at the outlet of conventional valve bodies (figure 3.24). The design
incorporates oversize end connections with a streamlined flow path and the ease of trim
maintenance inherent with cage-style constructions. Use of noise abatement trim
reduces overall noise levels by as much as 35 decibels. Also available in cage less
Versions with bolted seat ring, end connection sizes through 20-inch, Class 600, and
versions for liquid service. Flow direction depends on the intended service and trim
selection, with unbalanced constructions normally flowing up and balanced
constructions normally flowing down.
60
3.2.7- Different shapes of valves
Disc Type Plugs

61
Butterfly
62
63
Ball Plug
V Port Plug
3.2.8- Types of Actuator / Plug with respect to
Actions
There are four types
 Reverse Actuator/ Direct Plug
 Direct Actuator/ Direct Plug
 Direct Actuator/ Reverse Plug
 Reverse Actuator/ Reverse Plug
The operating force is derived from compressed air pressure, which is applied to a
flexible diaphragm. The actuator is designed so that the force resulting from the air
pressure, multiplied by the area of the diaphragm, overcomes the force exerted (in the
opposite direction) by the spring(s).
Fig. a (Direct Actuator/ Direct Plug) Fig. b (Reverse Actuator/ Direct Plug)
The diaphragm (Figure b) is pushed upwards, pulling the spindle up, and if the spindle
64
is connected to a direct plug, the plug is opened. The actuator is designed so that with a
specific change of air pressure, the spindle will move sufficiently to move the valve
through its complete stroke from fully-closed to fully-open.
.As the air pressure decreases, the spring(s) moves the spindle in the opposite direction.
The range of air pressure is equal to the stated actuator spring rating, for example 0.2 - 1
kg/cm2.
With a larger valve and / or a higher differential pressure to work against, more force is
needed to obtain full valve movement.
To create more force, a larger diaphragm area or higher spring range is needed. This is
why controls manufacturers offer a range of pneumatic actuators to match a range of
valves - comprising increasing diaphragm areas, and a choice of spring ranges to create
different forces.
The diagrams in Figure” a” show the components of a basic pneumatic actuator and the
direction of spindle movement with increasing air pressure.
The direct acting actuator is designed with the spring below the diaphragm, having air
supplied to the space above the diaphragm. The result, with increasing air pressure, is
spindle movement in the opposite direction to the reverse acting actuator.
Fig. c (Direct Actuator/ Reverse Plug)

The effect of this movement on the valve opening depends on the design and type of
plug used, and is illustrated in Figure a. There is however, an alternative, which is
65
shown in Figure “c” A direct acting pneumatic actuator is coupled to a control valve
with a reverse acting plug (sometimes called a 'hanging plug').
The choice between direct acting and reverse acting pneumatic controls depends on
what position the valve should revert to in the event of failure of the compressed air
supply. Should the valve close or be wide-open? This choice depends upon the nature
of the application and safety requirements. It makes sense for steam valves to close on
air failure, and cooling valves to open on air failure. The combination of actuator and
valve type must be considered. Figure “d” and Figure “e” show the net effect of the
various combinations.
Two part
valves
Actuator action Direct Reverse Reverse Direct

Plug action Direct Reverse Direct Reverse
On air failure Valve opens Valve closes

Fig. d Net effect of various combinations for two port valves
66
3.3- Cage
A part of a valve trim that surrounds the closure member and can provide flow
characterization and/or a seating surface. It also provides stability, guiding, balance,
and alignment, and facilitates assembly of other parts of the valve trim. The walls of the
Cage contains openings that usually determine the flow characteristic of the control
valve. Various cage styles are shown in figure.
Fig. 3.29
Characterization of Cage-Guided Valve Bodies
In valve bodies with cage-guided trim, the shape of the flow openings or windows in
the wall of the cylindrical cage determines flow characterization. As the valve plug is
moved away from the seat ring, the cage windows are opened to permit flow through
the valve. Standard cages have been designed to produce linear, equal-percentage, and
quick opening inherent flow characteristics. Note the differences in the shapes of the
cage windows shown in figure 3-29. The flow rate/travel relationship provided by
valves using these cages is equivalent to the linear, quick-opening, and equal-
percentage curves shown for contoured valve plugs (figure 3.30). Cage-guided trim in a
control valve provides a distinct advantage over conventional valve body assemblies in
that maintenance and replacement of internal parts is much simplified. The inherent
flow characteristic of the valve can be easily changed by install ling a different cage.
Interchange of cages to provide a different inherent flow characteristic does not require
67
Changing valve plug or seat ring. The standard cages shown can be used with either
balanced or unbalanced trim constructions. Soft seating, when required, is available as a
retained insert in the seat ring and is independent of cage or valve plug selection.
Cage interchangeability can be extended to specialized cage designs that provide noise
attenuation or combat cavitations. These cages furnish a modified linear inherent flow
characteristic, but require flow to be in a specific direction through the cage openings.
Therefore, it could be necessary to reverse the valve body in the pipeline
To obtain proper flow direction.
Figure 3-30. Inherent Flow

Characteristics Curves

Valve Plug Guiding
Accurate guiding of the valve plug is necessary for proper alignment with the seat ring
and efficient control of the process fluid. The common methods used are listed below
and their names are generally self descriptive.
Cage Guiding
The outside diameter of the valve plug is close to the inside wall surface of the
cylindrical cage throughout the travel range. Since bonnet, cage, and seat ring are self
aligning on assembly, correct valve plug/seat ring alignment is assured when valve
closes (figure 3-15).
Top Guiding
68
Valve plug is aligned by a single guide bushing in the bonnet or valve body
(figure 3-4), or by packing arrangement.
Stem Guiding
Valve plug is aligned with the seat ring by a guide bushing in the bonnet that acts on
the valve plug stem (figure 3-3, left view).
Top-and-Bottom Guiding
Valve plug is aligned by guide bushings in the bonnet and bottom flange (figure 3-7).
Port Guiding
Valve plug is aligned by the valve body port. This construction is typical for control
valves using small-diameter valve plugs with fluted
3.4- Packing Box (Assembly)

The part of the bonnet assembly used to seal against leakage around the member
stem. Included in the complete packing box assembly are various combinations of some
or all of the following component parts: packing, packing follower, packing nut, lantern
ring, packing spring, packing flange, packing flange studs or bolts, packing flange nuts,
packing ring, packing wiper ring, felt wiper ring, belle ville
Springs, anti-extrusion ring. Individual Packing parts are shown in figure 3.31.
Most control valves use packing boxes with the packing retained and adjusted by a
flange and stud bolts (figure 3.32). Several packing materials can be used depending on
the service conditions expected and whether the application requires compliance to
Environmental regulations. Brief descriptions and service condition guidelines for
several popular materials and typical packing material arrangements are shown in
figure 3.31.
Packing Assemblies
69
Fig. 3.31 Comprehensive Packing Material Arrangements for Globe-Style Valv Bodies
PTFE V-Ring
o Plastic material with inherent ability to minimize friction
o Molded in V-shaped rings that are spring loaded and self-adjusting in the
packing box. Packing lubrication not required
o Resistant to most known chemicals except molten alkali metals. Requires

extremely smooth (2 to 4 micro-inches RMS) stem finish to seal properly. Will
leak if stem or
Packing surface is damaged
o Recommended temperature limits:
o 40 to +450_F (−40 to +232_C)
o Not suitable for nuclear service because PTFE is easily destroyed by radiation.
Laminated and Filament Graphite
o Suitable for high temperature nuclear service or where low chloride content is

desirable (Grade GTN).
o Provides leak-free operation, high thermal conductivity, and long service life,
but produces high stem friction and resultant hysteresis.
o Impervious to most hard-to-handle fluids and high radiation. Suitable

temperature range: Cryogenic temperatures to 1200_F (649_C)
o Lubrication not required, but an extension bonnet or steel yoke should be used
when packing box temperature exceeds 800_F (427_C).
70
Single PTFE V-Ring Packing
(Fig. 3.32)
The single PTFE V-ring arrangement uses a coil spring between the packing and
packing follower. It meets the 100 ppmv criteria, assuming that the pressure does not
exceed 20.7 bar (300 psi) and the temperature is between −18_C and 93_C (0_F and
200_F). It offers very good sealing performance with the lowest operating friction.
Figure 3-32. Single PTFE V-Ring Packing

ENVIRO-SEAL_ PTFE Packing
(Fig. 3.33)
The ENVIRO-SEAL PTFE packing system is an advanced packing method that utilizes a
compact, live-load spring design suited to environmental applications up to 51.7 bar
and 232_C (750 psi and 450_F). While it most typically is thought of as an emission
reducing packing system, ENVIROSEAL PTFE packing is suited also to non
environmental applications involving high temperatures and pressures, yielding the
benefit of longer, ongoing service life.
Figure 3-33. ENVIRO-SEAL PTFE Packing System
71
ENVIRO-SEAL Duplex Packing
This special packing system provides the capabilities of both PTFE and graphite
components to yield a low friction, low emission, fire-tested solution (API Standard
589) for applications with process temperatures up to 232_C (450_F).
KALREZ_ Packing
The KALREZ pressure/temperature limits referenced are for Fisher valve applications
only. KALREZ with PTFE is suited to environmental use up to 24.1 bar and 204_C (350
psi and 400_F) and to some non-environmental services up to 103 bar (1500 psi).
KALREZ with ZYMAXX, which is a carbon fiber-reinforced TFE, is suited to 260_C (500
F) service.
Figure 3-34. ENVIRO-SEAL_ Duplex (PTFE and Graphite) Packing System

ENVIRO-SEAL_ Graphite ULF
(Fig. 3.35)
This packing system is designed primarily for environmental applications at
temperatures in excess of 232_C (450_F). The patented ULF packing system
incorporates very thin PTFE layers inside the packing rings as well as thing PTFE
washers on each side of the packing rings. This strategic placement of PTFE minimizes
control problems, reduces friction, promotes sealing and extends the cycle life of the
packing set.
72
Figure 3-35. ENVIRO-SEAL Graphite
ULF Packing System
HIGH-SEAL_ Graphite ULF
Identical to the ENVIRO-SEAL graphite ULF packing system below the packing
follower, the HIGH-SEAL system utilizes heavy-duty, large diameter Belleville springs.
These springs provide additional follower travel and can be calibrated with a load scale
for a visual indication of packing load and wear
Figure 3-36. ENVIRO-SEAL_ Graphite Packing System for Rotary Valves

ENVIRO-SEAL_ Graphite for Rotary Valves
(Fig. 3.36)
ENVIRO-SEAL graphite packing is
Designed for environmental applications from −6_C to 316_C (20_F to 600_F) or for
those applications where fire safety is a concern. It can be used with pressures
To 103 bar (1500 psi) and still satisfy the 500 ppmv EPA leakage criteria.
73
4. Control Valve Accessories
74
 To understand functions of control valves accessories.
 To study the advantages of control valves accessories.
 To study the types of control valves accessories.
o Positioner
o Air Regulator
o Quick Opening Relay
o Booster Relay
o Limiter Switch
o Hand Jack (Hand Wheel)
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This chapter offers information on digital valve controllers, analog positioners, boosters,
and other control valve accessories.
4.1- 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—a pneumatic signal (usually 3-15 psig) is supplied to the

positioner. The positioner translates this to a required valve position and supplies the
valve actuator with the required air pressure to move the valve to the correct position.
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 digital products cover three categories.
o Digital Non-Communicating: a current signal (4-20 mA) is supplied to the

positioner, which both powers the electronics and controls the output.
o HART: this is the same as the digital non-communicating but is also capable of
two-way digital communication over the same wires used for the analog signal.
o Field bus: this type receives digitally based signals and positions the valve using
digital electronic circuitry coupled to mechanical components. An all-digital

control signal replaces the analog control signal. Additionally, two-way digital
communication is possible over the same wires. Field bus technologies benefit
the end user by enabling improved control architecture, product capability and
reduced wiring. Use of a single, integrated analog I/P positioner or digital
controller (figure 4-1) instead of a combination of pneumatic positioner and
transducer (two instruments) results in lower installed cost.
The ability to embed software commands into the memory of the device represents the
real difference between digital and analog I/P segments.
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Figure 4-1. Modern Control Valves Utilizing Digital Valve Controllers
This allows automatic configuration and setup of the valve when equipped with a
digital controller. Most importantly, it allows two-way communication for process,
valve, and instrument diagnostics. Users purchase digital valve controllers for several
reasons:
o Reduced cost of loop commissioning, including installation and calibration.
o Use of diagnostics to maintain loop performance levels.
o Improved process control accuracy that reduces process variability. Two
aspects of digital valve controllers make them particularly attractive:
o Automatic calibration and configuration. Considerable time savings are
realized over traditional zero and spanning.
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o Valve diagnostics. Through the Distributed Control System (DCS), PC
software tools, or handheld communicators, users can diagnose the health of
the valve while it is in the line
. FIELDVUE
o Instruments enable new diagnostic capabilities that can be accessed remotely.
This single element requires a look at the potential impact of the technology as it
applies to control valves. An in-plant person, with the aid of the Flow Scanner
o System, can diagnose the health of a valve through a series of off-line tests. The
Flow Scanner system consists of a portable, ruggedized computer and travel and
pressure sensors. The sensors are connected to the valve to enable diagnostic
tests, which are conducted with the valve off-line. A skilled maintenance
technician can determine whether to leave the valve in the line or to remove the
valve for repair. Digital instruments allow an extension of this service with
added enhancements:
o Because sensors are part of the instrument, tests can be run easily at appropriate
times.
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o It is now possible to diagnose the health of a valve remotely via HART or
Foundation field bus.
o On-line diagnostics enable predictive maintenance without disrupting the
process.
These additional elements are extremely important. The remote capability allows
monitoring valves. Those who make, supply and service valves for a living now assist
the customer in the diagnosis of valve condition to a level never before possible.
Predictive maintenance offers additional savings for the customer. It is now possible to
See the performance of the valve as it operates. Watching performance decline over
time enables the user to predict when replacement or repair is necessary.
Other Control Valve Accessories

Figure 4-5 illustrates a top-mounted hand wheel for a direct-acting diaphragm actuator.
This unit can be used as an adjustable travel stop to limit travel in the upward direction
or to manually close push-down-to-close valves. Figure 4-6 illustrates a top-mounted
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Hand wheel for a reverse-acting diaphragm actuator. This unit can be used as an
adjustable travel stop to limit travel in the downward direction or to manually close
push-down-to open valves.
4.2- Limit Switches

Limit switches operate discrete inputs to a distributed control system, signal lights,
small solenoid valves, electric relays, or alarms. The cam-operated type (figure 4-7) is
typically used with
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Figure 4-5. Top-Mounted Hand wheel for Direct-Acting Diaphragm

Actuator
81
Figure 4-6. Top-Mounted Hand wheel for Reverse-Acting Diaphragm
Actuator
Two to four individual switches operated by movement of the valve stem. An assembly

that mounts on the side of the actuator houses the switches. Each switch adjusts
individually and can be supplied for either alternating current or direct current systems.
Other styles of valve-mounted limit switches are also available.
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Figure 4-7. Cam-Operated Limit Switches
4.3- Solenoid Valve Manifold

The actuator type and the desired failsafe operation determine the selection of the
proper solenoid valve (figure 4-8). The solenoids can be used on double-acting pistons
or single-acting diaphragm actuators.
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Figure 4-8. Solenoid Valve
4.4- Supply Pressure Regulator

Supply pressure regulators (figure 4-9), commonly called air sets, reduce plant air
supply to valve positioners and other control equipment. Common reduced-air-supply
pressures are 20, 35 and 60 psig. The regulator mounts integrally to the positioner, or
Nipple-mounts or bolts to the actuator
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Figure 4-9. Supply Pressure Regulator with Filter and Moisture Trap
A large screw, known as the set screw, sets the pressure that is desired. It can do
this by using the strength of the non-wetted steel springs. Those springs are linked to
the main shaft. These springs are forced down this shaft. The valve seat is made to stay
open because the springs are pushing down very hard. As the valve stays open, there is
a small tube at the opening of the valve that helps move pressure into the pressure
chamber. This pressure chamber has one major component, a large diaphragm that rolls
as the pressure intensifies and then rolls back down when the pressure lets go.
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When the pressure is increased, the diaphragm will roll opposite of the springs. When
the air pressure is more than the springs can handle, the diaphragm takes charge over
the springs. This will cause the springs to shrink together tightly and makes the main
shaft move upward. The valve seat shuts off to the small tube at the opening of the
valve. This will not let anymore pressure come through, and it will stay closed if the
pressure is over what you have pre-determined with the screw that manipulates the
springs. The majority of the time, regulators can find the right balance of pressure, so
you just have to make sure that the pressure is consistent and stable. Also, you want the
valve to remain opened a little and the pressure's force to go opposite of the diaphragm.
When pressure is regulated, the valve will open gradually and the springs will push the
main shaft down once again. This will only happen if the air pressure falls below the set
pressure desired, which was designated in the beginning.
Disadvantages of an Air Pressure Regulator

There are two things that they will not do. One, they will not act like a pump. They can
not turn low inward pressure into higher pressure. You must buy a special piece to do
this. Two, it will not handle back pressure.
Advantages of an Air Pressure Regulator

There are actually two benefits of having an air pressure regulator. The first is that it
helps with accuracy and can repeatedly match the springs to the range of pressure. The
second one is that not all air pressure regulators use metals. The newer ones use all
plastic, and this helps prevent corrosion. This is cost-effective and better for the
environment
4.5- Lock-Up Systems

Pneumatic lock-up systems (figure 4-10) are used with control valves to lock in existing

actuator loading pressure in the event of supply pressure failure. These devices can be
used with volume tanks to move the valve to the fully open or closed position on loss of
pneumatic air supply. Normal operation resumes automatically with restored supply
pressure. Functionally similar arrangements are available for control valves using
diaphragm actuators.
4.6- Fail-Safe Systems for Piston Actuators

In these fail-safe systems (figure 4-11), the actuator piston moves to the top or bottom of
the cylinder when supply pressure falls below a pre-determined value. The volume
tank, charged with supply pressure, provides loading pressure for the actuator piston
when supply pressure fails, thus moving the piston to the desired position. Automatic
operation resumes, and the volume tank is recharged when supply pressure is restored
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To normal.
4.7- Electro-Pneumatic Transducers

Figure 4-12 illustrates an electro pneumatic transducer. The transducer receives a direct
current input signal and uses a torque motor, nozzle-flapper, and pneumatic relay to
convert the electric signal to a proportional pneumatic output signal. Nozzle pressure
Operates the relay and is piped to the torque motor feedback bellows to provide a
comparison between input signal and nozzle pressure. As shown, the transducer can be
Mounted directly on a control valve and operate the valve without need for additional
boosters or positioners.
87
88
4.8- Electro-Pneumatic Valve Positioners
Electro-pneumatic positioners (figure 4-13) are used in electronic control
Loops to operate pneumatic diaphragm control valve actuators. The positioner receives
a 4 to 20 mA DC input signal, and uses an I/P converter, nozzle-flapper, and pneumatic
relay to convert the input signal to a pneumatic output signal. The output signal is
applied directly to the actuator diaphragm, producing valve plug position that is
proportional to the input signal. Valve plug position is mechanically fed back to the
torque comparison of plug position and input signal. Split-range operation capability
can provide full travel of the actuator with only a portion of the input signal range.
89
5. Troubleshooting
90
5.1- TABLE. Troubleshooting Diagram
Problems and Symptoms Causes Solutions
1. Seat ring-to-plug leakage 1a. Low load (bench set, 1a.Use proper surface
calibration, friction, etc.). preparation (lapping).
1b. Poor surface condition 1b.Correct actuator and valve
(lapping materials). setup (bench set, calibration,
friction, etc.).
2. Seat ring-to-body leakage. 2a. Low load (inadequate 2a. Correct bolt load, parts
torque, parts stack-up, stack-up, gasketing
improper gasketing). 2b. Recut, clean up gasket
2b. Surface condition face.
(cleanliness, finish). 2c. Porosity in casting can
2c. Porosity in body sometimes result in leakage
around gaskets. Check for
porosity. Grind out and weld
up.
3. Packing leakage 3a. Stem finish/cleanliness 3a. Clean up and polish stem
to 4 rms finish.
3b. Bent stem. 3b. Straighten stem to within
0.002 in. over stroking length.
3c. Low packing load. 3c. Retorque bolting or use
live-loading.
3d. Wrong packing type or 3d. Check packing type and
configuration. configuration. Against
application. Repack as
necessary.
3e. Excessive packing stack 3e. Install spacers to minimize
height (graphite.) packing height. Repack valve.
3f. Use sacrificial washers.
3f. Corrosion and pitting Remove graphite Packing if
(graphite). valve is to be inactive for
more Than 2 to 3 weeks.
3g. Seized or cocked packing 3g. Inspect and replace any
follower. damaged parts such
As flanges, nuts, and
followers.
3h. switch to high
performance packing system.
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Problems and Symptoms Causes Solutions
4. Sliding wear. 4a. High cycling (unstable 4a. Tune loops; reduce
loop?). friction to reduce
4b. Excessive contact stress. instability.
4c. Misalignment.
4d. Surface finish not to 4b. Increase bearing size.
specification. . 6c. Remachine parts to
4e. Incorrect materials correct alignment.
choice 4d. Polish surfaces.
4e. Review materials choice

in light of application.
4f. Switch to sliding-stem

globe-style
Valve because of better
guiding.
5. Bonnet-to-body leakage 5a. Low load from bonnet 5a. Retorque bolting. Check
bolting (torque, internal parts, parts stack-up against
stack-up, spring rate in drawings.
gasket).
5b. Surface finish. 5b. Retouch, clean up gasket
5c. Stud leaks faces.

5c Sometimes casting porosity
can let process. Fluid seep into
bottom of stud holes.
Leakage around studs looks
like leakage past bonnet
gasket (see Fig. 52).
Grind out and weld up

porosity.
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6. Loose stem connection. Or 6a. Improper torque or 6a. Purchase the stem and
broken stem. pinning. plug as an assembly.
6b. Vibration or instability
6b. Review trim-style
application.
8c. Reduce clearances between
cage and plug.
6d. Switch to a welded plug or

stem connection.
7. Excessive leakage past 7a. Cage finish too rough. 7a. Polish cage bore, check I.D.
piston seal. Cage I.D. too large. against drawings.
9b. Improper installation 9b. Replace seal, follow
Graphite rings, Omni seal. leakage is normal.
7c. Is leakage normal for the 7d. Change to high

type of seal? temperature design.
9d. Exceeding temperature
limitations for seal. 7e. Replace seal. Address loop
stability if cycling
7e. Seal simply worn out due Is caused by this.
to cycling
8. Valve will not respond to 8a. No air supply or low air 8a.Check the system in
signal. supply. accordance with the P&IDs.
8b. Leaks in actuator. Verify that all air supply

8c. Solenoid closed on inlet valves are open.
lines. 8b.Measure and verify
8d. No controller input signal. sufficient air supply pressure.
8e. Crimped, broken air lines. 8c. Listen for blowby at the
8f. Leaking air fitting. seals or diaphragm. Repair or
8g. Incorrect flow direction replace defective parts.
causing excessive loads on
plug. 8d. Actuate solenoid valve.
8h. Incorrect air line Replace if defective.
connections.
8i. Packing parts binding on 8e.No controller input may
stem or shaft. indicate a fuse has blown.
8j. Defective positioner or I/P. Replace.
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8k. Packing over tightened. 8f. Check all air lines to see
8l. Trim is seized. they are not crimped or
8m. Plug stuck in seat broken. Repair or replace.
8g. Check fittings for leaks.
Tighten or replace
8h. If the valve was just
installed, check the flow
arrow to ensure the process is
flowing in the proper
direction. Flow above the seat
can add pressures the actuator
may not be able to overcome.
Reverse flowing direction, if
appropriate.
8i. Check the air to and from a

piston actuator to ensure the
supply is not connected to the
exhaust and vice versa. Check
all connections.
8j. Check the packing gland.
Improper gland
Configuration is a primary
cause of rod binding.
Replace parts and polish trim.
8k. Check the positioner

and/or the I/P to see if
The output can be changed

manually. If not, it is
Defective. Repair or replace.
8l. Over tightened packing or

binding in guides
Can cause excessive friction
that blocks valve.
Loosen, lubricate, cycle, and
retorque.
8m. Replace or repair seized

trim. Damage may be
Polished out.
94
8n. Pull or machine plug out
of seat. Repair or
Replace affected parts.
9. Valve will not open to rated 9a. Insufficient supply 9a. Verify adequate supply
travel pressure. pressure.
9b. Leaks in the actuator or
accessories. And accessories. 9b. Stop all leaks in actuator,
9c. Incorrect positioner or I/P air lines fittings, and
calibration. accessories.
9d. Incorrect travel adjus11e.
Incorrect actuator spring rate. 9c. Correct positioner and/or
Tent. I/P calibration.
9f. Incorrect bench set.
9g. Bent stem or shaft 9d. Readjust valve travel.
9h. Damaged valve trim.
9i.Debris in trim 9e. Change actuator spring.
9j. Incorrect flow direction.
9k. Actuator is too small. 9f. Adjust bench set.
9l. Excessive packing friction.
9m. Incorrect position of 9g. Replace bent stem or shaft.
manual 9h. Replace damage trim.
Operator on travel stops.
9i. Clean out valve trim.
9j. Reverse flowing direction.
9k. Replace actuator.

9l. Loosen packing, cycle,

lubricates and retorque.
9m. Readjust manual operator

or travel stop.
95
10. Valve travel sluggish or 10a. Excessive packing 10a. Readjust or replace
slow. friction. packing.
10b. Stem or shaft bent 10b. Replace bent shaft or
10c. Inadequate supply stem.
pressure. 10c. Increase supply pressure.
10d. Inadequate supply 10d. Go to bigger supply line
volume. or add capacity at valve.
10e. Undersized accessories. 10e. Increase flow capacity of
10f. Excessive friction in Accessories.
piston-type actuator.
10g. Bearing friction. 10f. Clean out, polish cylinder
10h. Poor positioner response. I.D., remove excess lubricant.
10g. Repair or replace
defective bearings.
10h. Repair or replace
positioner.
11. Valve travel is jumpy. 11a. Stick-slip action in 11a. Loosen, lubricate
packing seals or bearings. packing. Replace or repair
11b. Volume booster bypass seals and bearings.
may need to be adjusted. 11b. Adjust booster bypass.
11c. Positioner may be 13c. Repair or replace

defective. positioners.
11d. Positioner gain may be
too high. 11d. Adjust positioner gain.
Replace with lower gain
model.
12. Rotary valve will not Rotary valves have some 12a. Readjust actuator stops.
rotate unique problems. In addition 12b. Replace shaft.
to those items already covered 14c. Replace damaged parts,
in items 10 and 11: readjust
12a. Actuator stops set wrong, Travel.
Stopping the valve 12d. Replace or clean parts.
mechanically before it fully 12e. Recheck actuator sizing
rotates. and valve service limits.
96
12b.Broken shaft. Change valve and/or actuator,
12c. Over travel can cause as appropriate.
severe damage to eccentric 12f. Loosen line bolting.
valves; valves can jam.
12d. Dirt or corroded valve
seats can cause broken stems
or valve can jam.
12e. Changing service
conditions,
higher pressures and greater
pressure drops may stop the
valve from rotating due to
insufficient
Torque, high bearing loads.
12f. Over tightened line
bolting
can increase friction between
the
Ball and seal.
13. Poor flow control and See items 12 and 13 relating to 13a. Replace cage.
(rotary and sliding stem). sluggish response “jumpy” 13b. Replace piston rings.
travel. Other causes include: 13c. Resolve sources of
13a. Deformed cage. damage. Replace parts.
13b. Damaged piston rings. 13d. Replace Shaft.
13c. Erosion, corrosion, and 13e. Reverse valve in line.
cavitations can alter trim 13f. Correct flow
profile. characteristic.
13d. A twisted shaft will 13g. Select valve assembly
indicate a position that is with control requirements

untrue in regard to disk and taken into account.
seat. The valve may indicate
full open or full closed and
may really be mid-range.
13e. Valve may be installed
backward.
13f. Incorrect selection of flow
characteristic.
13g. Low performance valve
package.
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Common Valve Maintenance Procedures
5.2- Packing Maintenance.

Valve packing is one of the more troublesome elements of control valve Operation.
As a result, the end user is often faced with the prospect of pulling it out and installing
a new set. The best way to do this is to take the bonnet off of the valve and then push
the old packing out from the bottom, using the following procedure. Note that this
procedure covers a sliding-stem globe-style valve, and, as such, it can be done in line.
For rotary valves, the procedure differs in
That there is no bonnet, so the valve has to be taken from the line to extract the packing
as indicated below:
1. Apply enough air pressure to the actuator to put the valve in an intermediate
position so that there is no residual stem load. Disconnect the actuator and valve
stems. Relieve the air pressure, and disconnect the actuator supply and any
leadoff piping.
2. Remove the yoke coupling, yoke locknut, or the yoke bolting, and remove the
actuator from the bonnet.
3. Loosen the packing flange nuts so that the packing is not tight on the valve plug
stem. Remove any travel indicator disk and stem locknuts from the valve plug
stem threads. Safety note: When lifting the bonnet, be sure that the valve plug and
stem assembly remains on the seat ring. This avoids damage to the seating
surfaces as a result of the assembly dropping from the bonnet after being lifted
part way out. The parts are also easier to handle separately. Use care to avoid

damaging gasket sealing surfaces. If the cage cannot be held in the body due to
gasket adhesion, control it so that it will not cause equipment damage or
personal injury should it fall unexpectedly.
4. Unscrew the bonnet bolting and carefully lift the bonnet off the valve stem. If the
valve plug and stem assembly start to lift with the bonnet, use a brass or lead
hammer on the end of the stem and tap them back down. Set the bonnet on a
cardboard or wooden surface to prevent damage to the bonnet gasket surface.
5. Remove the valve plug, the seat ring, and the cage. Note: All residual gasket
material must be removed from the cage gasket surfaces. If the gasket surfaces
are scored or damaged during this Process, smooth and polish them by hand,
sanding with 360-grit paper and using long, sweeping Strokes. Failure to remove
all residual gasket material and/or burrs from the gasket surfaces will Result in
leakage.
98
6. Clean all gasket surfaces with a good-quality degreaser. Remove and residual tin
or silver from all gasket surfaces.
7. Cover the opening in the valve body to protect the gasket surface and to prevent
foreign material from getting into the body cavity.
8. Remove the packing flange nuts, packing flange, upper wiper, and packing
follower. Carefully push out all the remaining packing parts from the body side
of the bonnet using a rounded rod or other tool that will not scratch the packing
box wall.
9. Clean the packing box and the related metal packing parts: packing follower,
packing box ring, spring or lantern ring, special washers, etc.
10. Inspect the valve-stem threads for any sharp edges that might cut the packing. A
whetstone or Emery cloth may be used to smooth the threads if necessary. They
can also be chased with a die.
11. Remove the protective covering from the body cavity, and install the cage using
new top gaskets. Install the plug and then slide the bonnet over the stem and
onto the studs. Lubricate the stud threads and the faces of the hex nuts. Replace
hex nuts and torque the nuts in a crisscross pattern to no more than one-quarter
of the nominal torque value specified. When all the nuts are tightened to that
torque value, increase the torque by one-quarter of the specified nominal torque
and repeat the crisscross pattern. Repeat this procedure until all the nuts are
tightened to the specified nominal value. Apply the final torque value again and,
if any nut still turns, tighten every nut again.
12. Install new packing and the metal packing box parts according to the appropriate
arrangement in the instruction manual. If desired, packing parts may be
prelubricated for easier installation. Slip a smooth-edged pipe over the valve
stem, and gently tamp each soft packing part into the packing box.
13. Slide the packing follower, wiper, and packing flange into position. Lubricate the
packing flange studs and other related parts and the faces of the packing flange
nuts. Replace the packing flange nuts. For spring-loaded TFE V-ring packing,
tighten the packing flange nuts until the shoulder on the packing follower
contacts the bonnet. For other standard packing types, tighten the packing flange
nuts to the recommended torque. For high-performance packing sets, adjust the
live-loading springs as indicated in the instruction manual.
14. Mount the actuator on the valve body assembly, and reconnect the actuator and
valve stems acceding to the procedures in the appropriate instruction manual.
15. Cycle the valve 20 to 30 times and recheck packing load. Packing can be replaced
with the valve in the line, but it is not recommended due to the increased risk of
stem or packing box damage. If it must be attempted, follow the above procedure
with the changes noted below:
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 Remove the packing loading parts so that the top of the packing rings can
be seen.
 Very carefully insert a corkscrew packing extraction tool into the packing
box and twist it into the top of the packing until it can be used to pull the
top packing ring out.
 Repeat this procedure until all the upper packing has been removed. If
there is a spacer or bushing below the packing or between the upper and
lower packing sets on a double arrangement, it usually has some type of
slot or extraction hole. If it does not, it will have to be left in place.
Assuming that it can be extracted, pull it out, and continue the above
process with any packing left below the spacer.
 Once all the packing and internal parts have been removed, do your best
to clean the box out and inspect for any signs of damage. This cleaning
and inspection will be very difficult to accomplish with the bonnet in
place.
 Normally you should remove the stem connector and the actuator so the
rings can be slid down over the stem. If this is not possible, split rings can
be used, and they can be forced onto the stem by twisting them until the
opening is large enough to slide over the stem. Split rings are not
recommended due to their propensity to leak. If they are used, make sure
to stagger the splits to reduce the potential for leakage.
 If any damage is found, the valve should be disassembled and the
situation corrected at the first opportunity. Effective corrective action
cannot be taken with the bonnet on the valve, and repacking with the
bonnet on the valve will improve packing performance for a limited time,
at best, if the stem or box is damaged in any way.
 Repack and reassemble as noted above, using split rings if the stem

connector was not removed.
100
5.3- Lapping the Seats
Lapping is procedure used to provide a better fit and surface finish between the valve
plug and the mating seat. It applies only to metal-to-metal seating and is normally used
for Class IV or V shutoff on control valves. Classes I, II, and III don’t require it and Class
VI nearly always requires soft seats. The plug and seat in their as-machined state do not
always fit together perfectly around their circumference. Imperfections in fit result in
excess leakage, so lapping is required to eliminate these imperfections and to make sure
that the two parts fit together as closely as possible. Lapping should be carried out as
follows:
1. Lapping should be done with the standard guiding in place to make sure that the
parts are lapped in the positions that they will be in once the valve is fully
assembled. For this reason, it is normally done with the bonnet in place.
FIGURE. Lapping tool used with spring.
2. With the seat ring in place in the body, apply a light coating of coarse grinding
compound (600 grit) to both the seat ring and the plug. If the seating surfaces are
made of stainless steel, use some white lead in the grinding compound to keep it
from tearing or galling. Insert the plug and stem into the body and assemble the
bonnet onto the body opening. The bonnet does not have to the bolted into place
as long as the guiding simulates actual service.
101
3. Lapping requires that a very light load be applied to keep from tearing the metal,
so if the plug is heavy, a spring should be used to support some of the load. The
spring can be inserted over the stem and then a piece of strap iron can be locked
into place on the stem and used as a grinding handle (Fig. 53).
4. Gently rotate the plug and stem four or five times, over about a 45◦ arc. Pick it up
and move to a new position and repeat. Continue this procedure, lapping over
the entire circumference at least once. Pull the assembly apart, clean he surfaces,
and look for a fine continuous lap line on both the plug and the seat. Using a
mirror will make the line easier to see on the seat ring inside the valve body.
5. If the lap lines look good, reassemble and repeat the procedure with a fine grit
compound. If the lap lines are not continuous, repeat with the course compound.
If they are still not continuous, repeat with the course compound. If they are still
not continuous, try coining the surfaces by hitting the top of the stem two or
three times with a heavy, but soft hammer, and lap again. If this still doesn’t
provide the desired results, the plug and seat should be remachined to provide a
better initial fit and the process restarted.
6. When the fine grinding is done, thoroughly clean the surfaces and reassemble,
torquing the bonnet in place. If possible, a seat-leak test should then be carried
out to ensure tight shutoff.
7. High-temperature valves should be heated, if possible, before beginning this
process to better duplicate actual guiding and fit in service.
8. Double-ported bodies will never seal as well as a single-port design, but they can
still be lapped to improve shutoff. Special considerations for these valves
include: The top seat grinds faster than the bottom. Use a coarser grit on the
bottom ring to help correct for this. Never leave one seat dry while grinding the
other one. This will tear the metal and hurt the shutoff. Heavy grinding on one

seat may be required to get the two seats to contact at the same time.
9. Note that despite claims to the contrary, blue-lining to check for seat contact will
not provide the same tight shutoff seen with lapping. Tests have shown that
there can still be relatively large imperfections present even though the blue-line
shows continuous contact between the two surfaces.
102
5.4- Replacing the Actuator Diaphragm
After isolating the valve assembly from all pneumatic and/or fluid pressures, relieve
spring compression in the spring, if possible. (On some spring and diaphragm
Actuators for use on rotary-shaft valve bodies, spring compression is not externally
adjustable. Initial spring compression is set at the factory and does not need to be
relieved in order to change the diaphragm.) Remove the upper diaphragm case. On
direct-acting actuators, the diaphragm can be lifted out and replaced with a new one.
On reverse-acting actuators, the diaphragm head assembly must be dismantled to
change the diaphragm. Most pneumatic spring and diaphragm actuators utilize a
molded diaphragm for control valve service. The molded diaphragm facilitates
installation, provides a relatively uniform effective area throughout the valve’s range,
and permits greater travel than could be possible if a flat-sheet diaphragm were used. If
a flat-sheet diaphragm is used in an emergency repair situation, it should be replaced
With a molded diaphragm as soon as possible.
When reassembling the diaphragm case, tighten the cap screws around the perimeter of
the case firmly and evenly to prevent leakage. Be careful not to tear the diaphragm in
the area of the bolt holes during reassembly. Avoid reusing a diaphragm since they are
prone to leak if reused.
5.5- Replacing threaded-in seat rings

Threaded-in seat rings are no longer the preferred design for control valves in the
chemical process industry. Nevertheless, this design is encountered fairly often
Due to its popularity in the past. The main reason this design has fallen from favor is
that the seat rings can be very difficult to get out. Adhering to the following
recommended practice should help extract the seat ring with a minimum of effort and
risk of personnel:
1. Before trying to remove the seat ring(s), check to see if it has been tack-welded
into the body. If it has, grind out the weld.
2. To make disassembly easier, soak the ring and threads with penetrating oil and
allow them to sit for some time so that the oil can do its job in loosening up the
threads.
3. Insert a seat ring puller like that shown in Fig. 54 against the lugs or in the slots
of the ring. Be careful to hold the puller down against the ring while applying
torque, and any rounded edges on the lugs or slots should be corrected to keep
the puller from slipping past the lugs or slots.
103
FIGURE. Seat ring puller
4. The torque can be applied manually or with the aid of a hydraulic torque
wrench. If the power wrench is used, be extra careful to avoid slippage due to the
high torques and the safety risk to personnel if something slips or breaks. If the
valve has been pulled from the line, a lathe or boring mill may be the easiest way
to apply the torque to back the ring out.
5. The bonnet bolting can be used as a reaction point for the torque and to hold the
puller down into the body.

6. On particularly stubborn rings, using an impact wrench can help to break them
loose.
7. As the ring starts to come out, the bolts holding the puller in the body must also
be loosened to permit the ring to move up.
8. Once the ring is out, thoroughly clean and chases all threads.
9. Apply a heavy coat of lubricant or pipe compound to all threads and reinstall and
torque to specified
104
105

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Process Valves and Accessories

PAKARAB FERTILIZERS LIMITED MULTAN

1. Introduction to Control Valve

1.1 What is Control Valve?

2. Types of Control Valve

2.1 Linear Motion

2.2 Rotary Motion

2.2.1 Butterfly Valve

3. Control Valve Parts

3.1.1 Diaphragm Type Actuator

3.2.1 Parts of Valve Body

4. Control Valve Accessories

5.1 Table for Troubleshooting

Process Valves and Accessories | GEN-03 (Rev 0)

Process Valves and Accessories | GEN-03 (Rev 0)

Rated Flow Coefficient (CV)

Equal Percentage Characteristic

Quick Opening Characteristic

Process Valves and Accessories | GEN-03 (Rev 0)

Final Control Element

Closure Member Guide

Process Valves and Accessories | GEN-03 (Rev 0)

Diaphragm Pressure Span

Process Valves and Accessories | GEN-03 (Rev 0)

Types of Control Valve

2.1- Linear Motion Control Valve

Process Valves and Accessories | GEN-03 (Rev 0)

Fig.2.1 A typical sliding stems Control Valve with a pneumatic Actuator

Process Valves and Accessories | GEN-03 (Rev 0)

Fig.2.3 Single SEATED Globe Valve

Process Valves and Accessories | GEN-03 (Rev 0)

2.1.2- Double Seated Valve (Double-Port Valve Bodies)

 A double-seated value is generally top and bottom guided.

Fig. 2.5 Reverse-Acting Double-Ported Globe-Style Valve Body

Process Valves and Accessories | GEN-03 (Rev 0)

2.1.3- Angle Valve

Fig.2.6 Angle Valve

Process Valves and Accessories | GEN-03 (Rev 0)

Fig. 2.7 in let Port of Angle Valve

 Three pipeline connections provide general converging (flow-mixing) or

Fig. 2.8 Three Way Valve

2.1.5- Gate Valve

Process Valves and Accessories | GEN-03 (Rev 0)

Fig. 2.11a Fig. 2.11b

Gate valves are classified as either RISINGSTEM or NONRISING-STEM valves.

Fig.2.12 Butterfly Control Valve Body

Process Valves and Accessories | GEN-03 (Rev 0)

2.2.2- V-Notch Ball Control Valve

2.2.3- Eccentric-Disk Control Valve Bodies

Process Valves and Accessories | GEN-03 (Rev 0)

Figure .2.14 Eccentric-Disk Rotary-Shaft Control Valve

 Bodies offer effective throttling control.

 They use standard pneumatic diaphragm or piston rotary actuators.

2.2.4- Eccentric-Plug Control Valve Bodies

Figure 2.15. Sectional of Eccentric- Plug Control Valve Body W4170/IL

2.2.5- Ball Valve

Process Valves and Accessories | GEN-03 (Rev 0)

Fig. 2.16 Ball Valve

Fig. 2.17 Cross section of a Characterized Ball Control Vale

Process Valves and Accessories | GEN-03 (Rev 0)

Fig. 2.18 Rotary Plug Valve

especially useful on services involving corrosive fluids, viscous liquids, or suspended

Process Valves and Accessories | GEN-03 (Rev 0)

Process Valves and Accessories | GEN-03 (Rev 0)