6.

13 Miscellaneous Valve and Trim Designs X

FY

C. S. BEARD (1970, 1985) B. G. LIPTÁK (1995)

J. P. WILSON (2005)
Expansible tube or
diaphragm valves

Control
pilot line

Fluid interaction valves

Flow sheet symbols

Valve and Trim Designs: A. Anticavitation Valves

B. Dirty Service Valves
C. Low-Noise Valves
D. High-Capacity Valves
E. Cryogenic Valves
F. High-Temperature Valves
G. Steam Conditioning Valves
H. Tank Mounted Valves
I. Expansible Tube or Diaphragm Valve
J. Fluid Interaction Valves

Available Range of Sizes: A. 1 to 36 in. (25 to 915 mm)

B. 1 to 36 in. (25 to 915 mm)
C. 1 to 48 in. (25 to 1220 mm)
D. 12 to 72 in. (300 to 1830 mm)
E. 1 to 36 in. (25 to 915 mm)
F. 1 to 20 in. (25 to 508 mm)
G. 6 to 48 in. (152 to 1220 mm)
H. 4 to 24 in. (100 to 600 mm)
I. 1 to 12 in. (25 to 300 mm)
1
J. /2 to 4 in. (12.5 to 100 mm)

Design Pressure Limits: A. Up to 8000 PSIG (550 bar)

B. Up to 8000 PSIG (550 bar)
C. Up to 4000 PSIG (275 bar)
D. Up to 3000 PSIG (205 bar)
E. Up to 1500 PSIG (100 bar)
F. Up to 5000 PSIG (345 bar)
G. Up to 5000 PSIG (345 bar)
H. Up to 1500 PSIG (100 bar)
I. Up to 1500 PSIG (100 bar)
J. 100 PSIG (7 bar) or greater (no theoretical limit)

Maximum Operating A. Up to 1100°F (595°C)

Temperatures: B. Up to 1100°F (595°C)
C. Up to 1100°F (595°C)
D. Up to 1100°F (595°C)
E. –325°F (–162°C) to 300°F (150°C)
F. Up to 1800°F (980°C)
G. Up to 1100°F (595°C)

1199

© 2006 by Béla Lipták

1200 Control Valve Selection and Sizing

H. Up to 1100°F (595°C)
I. Up to 150°F (66°C)
J. Can handle molten metals

Partial List of Suppliers: ABB Process Automation (www.api-usa.com)

Emerson Process Management–Daniel Division (www.daniel.com)
Emerson Process Management–Fisher Valve Division (www.fisher.com)
Flowserve Corporation (www.flowserve.com)
Masoneilan Division of Dresser Flow Control (www.masoneilan.com)
Siemens (www. siemens.com)

INTRODUCTION MISCELLANEOUS VALVE DESIGNS

This section consists of two distinct parts. In the first part, a
number of control valve designs are described, which are
different in that they are neither linear nor rotary in their
operation. These miscellaneous valve designs utilize the
energy content of the flowing fluid for their operation. They
depend on fluid interaction or the static pressure of the pro-
cess fluid and use flexible elements to throttle gas pressure
regulators and other control valves. These valves are used in
specialized services, such as in sensitive level control, in gas
pressure or flow regulation, and in toxic services.
In the second part of this section some of the special
valve trim designs used in the traditional globe control valves
are discussed in terms of their suitability for specialized
applications. These applications include applications where
noise; cavitation; flashing; high and low temperatures or pres-
sures; or viscous, dirty, or slurry flows are involved.
Such trim designs and applications have already been
discussed in Sections 6.1, 6.7, 6.14, and 6.15.
Dynamically Balanced Plug Valves
This family of control valves has been developed for pres-
sure and flow control applications where no external power
is available to operate the valve, and therefore the static
pressure of the process fluid is utilized to achieve throttling.
Figure 6.13a illustrates an installation for upstream (back)
pressure control.
Here, the upstream pressure is sent to the control pilot
through port D. If the controlled upstream pressure drops, this
lowers the pressure in the pilot chamber and the pilot spring
moves the pilot poppet valve to the right. This opens port B
and thereby upstream pressure is applied inside the plug cham-
ber. This equalizes the pressure acting on the plug and allows
the spring to move the plug to the left, to close the valve.
These valves provide nearly linear characteristics
(Figure 6.13b) and high flow capacities (Cv = 30d ). They
2
are available in sizes up to 12 in. (300 mm), and special units

Controlled
pressure

D
A B C
E

B
A C Pilot valve
poppet assembly
Hard faced
plug

Plug guiding
provides stable
and consistent
seating.

Seat with
Plug chamber with
tight-shut-off
low-force spring

FIG. 6.13a
Dynamically balanced valve plug. (Courtesy of Daniel Industries.)

© 2006 by Béla Lipták

 6.13 Miscellaneous Valve and Trim Designs 1201

Closing Opening
port port
100

90
Dynamically
80 balanced
plug
70
Plug
% Flow or Cv

60
Expansible
50 tube
40

30
Piston
20
Cylinder
10
FIG. 6.13c
Positioned plug valve in its fully open position. (Courtesy of Eisen-
10 20 30 40 50 60 70 80 90 100
werk Heinrich Schilling.)
% Stroke

FIG. 6.13b
The characteristics of expansible tube and dynamically balanced one of the dynamic seals should fail. All seats and seals are
plug valves are nearly linear. replaceable by separation at the body flange.
The unit is particularly adaptable to fluids that are toxic
have been made in up to 24 in. (600 mm) sizes. The valves or difficult to contain, such as nitrogen tetroxide, hydrogen,
can be provided with up to ANSI Class 1500 rating and with and others used in the aerospace industry. The unit is fur-
1
pressure control settings up to 3000 PSIG (205 bar). nished in sizes from 1 /2–18 in. (37.5–450 mm), with ratings
The advantages of this design include its erosion and to 2500 PSIG (17.3 MPa). All types of end connections are
corrosion resistance, due to the hard facing of the plug; its available, and control is dependent upon the auxiliary control
good pressure recovery characteristics, due to the large and components selected for the application. An explosionproof
smooth annular flow area through the valve; its fast speed of limit switch can be furnished for position indication.
response; and its bubble-tight seating.
Diaphragm-Operated Cylinder In-Line Valves An in-line valve
Positioned Plug In-Line Valves using a low convolution diaphragm for positive sealing and long
travel (Figure 6.13f) is designed particularly for gas regulation.
The positioned plug in-line valve, excluding control units,
The low level of vibration, turbulence, and noise of this in-line
resembles a pipe spool. It is only necessary to inject pressure
design makes it suitable for high-pressure gas service.
into its ports for positioning the valve plug. This simple design
(Figure 6.13c) requires only three pressure seals. The plug is
carried on a cylinder that also includes the piston. Pressure in
Opening Closing
one port causes closing, while the opposite port is used for port port
opening. The valve has only one moving part and is available
in sizes from 2–8 in. (50–200 mm) for use to 350 PSIG at
400°F (2.4 MPa at 204°C). Control quality is dependent upon
the pilot valves and auxiliary units employed.
Another in-line valve available in small sizes (Figure 6.13c)
carries the valve plug on a bridge in the operating cylinder, with
the seat as part of a split body.
A spring-loaded version of this design uses the beveled
end of the moving cylinder to seat on a replaceable soft seat,
retained in a dam, held in position by struts from the inside
wall of the valve body. The spring loading may cause fail-
close or fail-open actions, as illustrated in Figure 6.13e. The
unit can be powered with line fluid or by an external pressure FIG. 6.13d
source. A double-bleed feature can be incorporated to elim- Positioned plug valve in closed position. (Courtesy of Control
inate the possibility of actuation and line fluids combining if Air Inc.)

© 2006 by Béla Lipták

1202 Control Valve Selection and Sizing

Opening Opening
port port
Closing Closing
port port

Fail closed design Fail open design

FIG. 6.13e
Spring-loaded positioned plug valve.

Inlet pressures to 1400 PSIG (9.7 MPa) and outlet pres-
sures to 600 PSIG (4 MPa) are possible in the 2 in. (50 mm)
size. It is a high-capacity valve, as expressed by Cv = 23 d . As
2 The expansible element in these valve designs can be a rubber
a gas regulator the unit is supplied with a two-stage pilot to
accept full line pressure. This pilot resists freeze-up and serves
as a differential limiting valve. All portions of the pilot and line
valve will withstand a full body rating of 600 PSIG (4 MPa).
Expansible Valve Designs
cylinder, an expansible tube, or an expansible diaphragm.
The common feature of all of these designs is that they utilize
the process pressure to provide tight shut-off of gas flows.
Expansible Element In-Line Valves Streamlined flow of gas
occurs in a valve in which a solid rubber cylinder is expanded
or contracted to change the area of an annular space
(Figure 6.13g). A stationary inlet nose and discharge bullet
allow hydraulic pressure to force a slave cylinder against the
rubber cylinder to vary its expansion. Control is from a dia-
phragm actuator, with the diaphragm plate carrying a piston.
The piston acts as a pump to supply hydraulic pressure to the
slave cylinder.
The rubber cylinder offers the seating ability of a soft seat
valve. It has the capability of closing over foreign matter, and

Rubber
Hydraulic
cylinder
fluid

Inlet pressure Loading pressure

Pilot supply pressure Outlet pressure

FIG. 6.13f FIG. 6.13g

Diaphragm-operated cylinder-type in-line valve used in high-pressure A rubber cylinder provides the soft seat in this low-noise, expand-
gas regulation services. able element, pressure regulator in-line valve.

© 2006 by Béla Lipták


Outlet
slots
Inlet
slots Closed Throttling
FIG. 6.13h
An expansible tube valve utilizes the process pressure for its operation, while being controlled by a three-way pilot that determines if the
valve is to be closed (left), throttling (center), or open (right).
the design allows for the use of a restricted throat for reduced
capacity. With this design, pressure drops as high as 1200 psid
(8.3 MPa) have been handled with a low noise level. The valve
may be utilized as a pressure reducer or for back-pressure
control, depending upon the system requirements.
Available sizes are 1–6 in. (25–150 mm). The 1 in. (25 mm)
valve can have screwed connections, while all sizes can be
flanged. The body is steel with flange ratings to 600 PSIG (4 MPa).
A valve positioner can be used, if the stem position is
calibrated as a function of the annular space reduction. If
such calibration is provided, a controller output can throttle
the valve to obtain accurate flow control.
Expansible Tube Valves Control of flow is obtained by use
of an expansible tube that is slipped over a cylindrical metal
core containing a series of longitudinal slots at each end and
a separating barrier in between. The characteristics of such
a valve were shown in Figure 6.13b.
A cylindrical, in-line jacket surrounds the tube so that
the process pressure can be introduced between the jacket
and the sleeve to cause the sleeve to envelope the slots. This
valve will open if the space between the jacket and the sleeve
is connected to the downstream (lower) pressure and will open
if that space in connected to the upstream (higher) pressure.
With pressure connected to the downstream line
(Figure 6.13h, right), the line pressure in the valve body will
cause the valve to open fully. Control of the pressure on the
sleeve creates a throttled flow condition by first uncovering the
inlet slots and then progressively opening the outlet slots
(Figure 6.13h, center). A continuous dynamic balance between
fluid pressure on each side of the sleeve makes it possible to
obtain wide rangeability between a no-flow and a full flow
(fully open) condition.
The basic operation of the valve can be accomplished
with a three-way pilot valve positioned from a remote loca-
tion. A variety of automatic pilots give versatility to the
basic valve. For reduced pressure control, a pilot is used to
© 2006 by Béla Lipták
6.13 Miscellaneous Valve and Trim Designs 1203
Open
modulate the jacket pressure in response to the sensed pres-
sure in the downstream pipeline.
As downstream pressure falls below the set point, the
double-acting pilot positions itself to reduce the jacket pres-
sure. This allows the valve to open to a throttling position.
Therefore, downstream pressure increases to the set pressure,
with attendant change in flow rate to maintain the set pressure.
The static sensing line is separate from the pilot discharge line,
in order to eliminate the pressure drop effect in the sensing line.
Another form simulates a conventional regulator, in that
system gas is bled into the jacket annular space through a fixed
orifice and bled off through the pilot regulator. In this form,
the static sensing line and pilot output are common. Double-
acting pilot systems use seven control ranges from 2 to 1200
PSIG (0.02–8.3 MPa) with corresponding inlet pressures up
to 1500 PSIG (10.4 MPa). The fixed orifice design is available
for control from 2 oz–600 PSIG (0.86 kPa–4 MPa).
Pilot Design Variations Back-pressure control and pressure
relief are obtained in the same manner as pressure reduction
is, except they sense the upstream pressure. By using a sep-
arate sensing and bleed port, a build-up from cracking to
fully open can be varied from 3 to 14% of the set pressure.
Return to normal operation causes the valve to create absolute
shut-off. Emergency shut-off service may use an external
pressure source piloted to obtain immediate shut-off upon
abnormal conditions.
A diaphragm-operated, three-way slide valve may also
control jacket pressure by proportioning the inlet and outlet
pressures. In this design, the controller output signal is sent to
the diaphragm actuator of the three-way slide valve, which causes
the sleeve valve to open proportionally, in a manner similar to
that of a conventional diaphragm control valve. In this manner,
the valve becomes a throttling control valve (Figure 6.13i).
Differential pressure or flow control is accomplished by
using a pilot valve in which the diaphragm is positioned by
both upstream and downstream pressures. The differential
1204 Control Valve Selection and Sizing

Control signal the normal pressure is controlled by pilot #1. An increase in

flow is sensed by the flow element (orifice, or flow tube), which
opens a high-differential pilot to cut in a boost-pressure-control
regulator (pilot #2), which has a higher set point than pilot #1.
Return to normal flow cuts out the boost pressure control
regulator and reinstates the normal control pilot.
The expansible tube valve is made in sizes from 1–12 in.
(25–300 mm) with pressure rating from 200 PSIG (1.4 MPa)
in iron to 1500 PSIG (10.3 MPa) in steel construction. It is
made flanged or flangeless for insertion between line flanges.
The flangeless body is cradled in the studs between the line
flanges. Removal of the body is made easier by expanding
the flanges about 1/8 in. (3 mm) using nuts on the studs inside
the flanges.
Tight shut-off or throttling requires a differential between
the line pressure or external source used for closure and the
downstream pressure sensed on the inside surface of the
sleeve that is exposed to this pressure. This differential
FIG. 6.13i requirement for a special low-pressure 2 in. (50 mm) valve
The expansible tube valve becomes a throttling control valve if it is is 3.6 psid (24.8 kPa) and is 1.6 psid (11 kPa) for a 4 in.
provided with a three-way slide-valve-type control pilot. (100 mm) valve. The low-pressure series requires from 21
psid (145 kPa) for the 1 in. (25 mm) size to 4.6 psid (32 kPa)
for the 10 and 12 in. sizes (250 and 300 mm). High-pressure
static lines may be taken at the inlet and outlet of the line
models require from 58 psid (400 kPa) for the 1 in. (25 mm)
valve or, for flow control, across an orifice plate in the line.
size to 11 psid (76 kPa) for the 10 and 12 in. sizes (250 and
300 mm).
Pressure Boosting A practically unlimited variety of pres-
The body design allows tight shut-off, even with com-
sure and flow regulators can be configured with the range of
pilots that are available. One important application is in pres- paratively large particles in the flow stream. Freezing of the
sure boosting in gas distribution systems. By these boosters, pilot by hydrates is not common because the intermittent and
the line pressure losses due to increased consumption can be small bleed occurs only to open the valve and as such is not
counteracted automatically by increasing the set pressure of conducive to freezing.
the distribution control valve. The pilot may be heated or housed, or even located in a
In such a design, there can be as many as three pilots protected area close to the warm line. With its only moving
controlling the gas distribution control valve. In Figure 6.13j, part a flexible sleeve, this type of valve has no vibration to
contribute to noise. The flow pattern also helps make this
valve from 5 to 30 db more silent than most regulators. Flow
Normal capacities are comparable to those of single-seated as well
Boost pressure control
pressure
(opens at high flow)
as many double-seated regulators.
control
Variable (pilot #1)
orifice Expansible Diaphragm Design In an expansible diaphragm-
type regulator, an expansible element (Figure 6.13k) is stretched
down over a dome-shaped grid causing shut-off of the valve
when pressure above this resilient member overcomes the line
pressure under the element. Line pressure is evenly directed
over the expansible area by a series of pressure channels.
Selection of the correct action on a pilot that supplies
line or external pressure to the exterior of the expansible
Boost Flow element causes the valve to control as a back-pressure or as
pressure element
a reducing control valve. For back-pressure control, or pres-
control
sure relief, the static line is taken upstream of the valve.
(pilot #2)
Increase in line pressure will increase the bleed from the
FIG. 6.13j annular space between the expansible element and the metal
Expansible tube-type gas distribution control valve can automati- housing. Reducing regulation is accomplished by restricting
cally boost the distribution pressure, when the demand for gas the bleed upon increase in downstream pressure and increas-
increases. ing it upon decrease in downstream pressure.

© 2006 by Béla Lipták

 6.13 Miscellaneous Valve and Trim Designs 1205

Splitter

PR
PL

Closed Control
ports
closed

FIG. 6.13l
The Coanda effect is used in the “flip-flop” diversion of flow in the
fluid interaction valves.

70% recovery of potential energy occurs in a diffuser section.

Fifty percent recovery is guaranteed for commercial valves,
and somewhat less for gases above critical flow and for vis-
Wide open
cous fluids (∆ P ~ P1/2).
Installation must allow the recovered pressure to create
FIG. 6.13k
The expansible diaphragm valve can be used as either a pressure the desired flow against friction effects of piping or fittings.
regulator or as a back-pressure relief valve. An uninhibited flow will create some aspirating effects in the
open outlet; restriction causes blocking, while excessive
restriction will cause a leak or diversion to the open port.

The valve is available in iron or steel with ratings to
600 PSIG (4 MPa). Models are available from −10–150°F
(−23–66°C), using a molded, Buna-N diaphragm. Relief valve
pressures are from 30–300 PSIG (0.21–2.1 MPa), while reduc-
ing service varies from 5–150 PSIG (0.03–1 MPa). Capacity
factors vary from Cv = 11 d in smaller sizes to Cv = 14 d in
2 2
larger valves.
Fluid Interaction Valves
Fast Level Control Industrial valves, with their ability to
divert in less than 100 ms, fill a wide variety of uses. The
primary one is for level control in which the effluent not
required for filling may be returned to storage. It is necessary
only to use a dip tube set at the control point, as shown in
Figure 6.13m. Lack of moving parts or of detrimental effects
due to fast diversion action allows the system to provide close
control.

The Coanda effect, the basis of fluidics, is used in diverting Converging

valves from 1/2–4 in. sizes (12.5–100 mm). The Coanda effect walls
means the attachment of a fluid stream to a nearby side-wall
of a flow passage. This effect can be used in a so-called “flip-
Valve
flop” valve for diverting a stream from one discharge port to
inlet
another.
Figure 6.13l shows the flow through the right-hand port
Side walls
due to both control ports being closed. Opening the right-hand Dip tube
Control
port, to allow air or liquid to enter, will shift the flow. The port Level fluctuates about
industrial valve has rectangular diverting tubes, but the end end of dip tube
connections may be circular. Control is maintained by opening
or closing the control port or by injecting low-pressure air or
liquid through a solenoid or other pilot valve.
In this valve, with stream flowing in one diversion tube,
the flow at the inlet contains some potential (pressure) energy FIG. 6.13m
and some kinetic (flowing) energy. Much of the potential The response of level control with fluid interaction diverting valves
energy is converted to kinetic energy at the nozzle. Up to can be very fast.

© 2006 by Béla Lipták

1206 Control Valve Selection and Sizing
Numerous uses of diversion valves exist, such as tank
filling, which is accomplished by using an external signal.
Diversion of a process stream upon contamination, sensed
by a pH or other analyzer, is important in paper mills and in
chemical plants.
The ability to divert rapidly makes this valve applicable
to oscillating flows. The valve may be used for space condi-
tioning, if the total bypassing of a heating or cooling medium
is adequate for space temperature control.
Fluidic valves can also be used for the diversion of engine
exhaust gases from tailpipe propulsion nozzles to wing-
mounted lift fans with ambient control flow. Other unique appli-
cations include a four-ported fluidic valve, which has been used
for direction control of a missile. It seems that all the potential
uses of this valve design have not been exploited yet.
SPECIAL VALVE APPLICATION
In the following paragraphs, the capabilities of one control
valve manufacturer (Fisher Controls) are discussed in han-
dling such demanding services as cavitation and sludge. This
is somewhat redundant, because Section 6.1 has already cov-
ered all the special control valve applications. These included
the products of all valve manufacturers and covered noise,
cavitation, flashing, high and low temperature or pressure
services, and viscous, dirty, or slurry flows.
Yet, the editor believes that this “manufacturer’s perspec-
tive” that follows is still a valuable addition to the overall
picture. The reader is reminded that Sections 6.14 and 6.15
provide in-depth information on control valve noise and on
valve sizing aspects of the various special applications. For
these reasons, the reader is advised to refer to the above-
mentioned sections for an in-depth treatment of the subject
matters that are discussed below.
Cavitation and Flashing
As it was already discussed in Section 6.1, a fluid will flash
when the downstream pressure is below the vapor pressure
of the flowing process fluid. The vapor bubbles that form
when the pressure falls below the vapor pressure continue to
grow as long as the pressure keeps dropping, and eventually
the liquid changes or flashes to a vapor.
In connection with Figure 6.1w, cavitation has been also
explained as it was also shown how vapor bubbles can be
formed at the vena contracta and how these bubbles can
implode and release powerful microjets that will damage any
metallic surface, as the pressure rises downstream. In addi-
tion, the options available to the process control engineer to
eliminate cavitation were also shown in connection with
Figure 6.1x.
There are a number of ways to protect against cavitation.
As was shown in Figure 6.1aa, one of the most common is
© 2006 by Béla Lipták
to expose the fluid to a series of restrictions as opposed to a
single restriction. Each subsequent restriction dissipates a
certain amount of the available energy and reduces the inlet
pressure to the next stage.
As was shown in Figure 6.1x, a well-designed pressure-
staging device prevents cavitation by taking a large pressure
differential and by maintaining the vena contracta pressure
above the vapor pressure of the liquid, which prevents the
liquid from cavitating.
The expanding flow area concept of damage control is
closely related to the pressure drop staging approach
(Figure 6.13n). Figure 6.13n shows a pressure vs. distance
curve for flow through a series of fixed restrictions where
the area of each succeeding restriction is larger than the
previous. Notice that the first restriction takes the bulk of
the pressure drop, and the pressure drop through successive
sections decreases.
In the last restriction, where cavitation is most likely to
occur, the pressure drop is only a small percentage of the
total drop, and the pressure recovery is substantially lower.
The expanding flow area concept requires fewer pressure
drop stages to provide the same cavitation protection as
does the concept that utilizes nearly identical areas for
staging.
The most common approach to cavitation protection
employs a drilled-hole cage that incorporates both pressure
staging and expanding flow area concepts. Each drilled hole
has a significant impact on the overall pressure recovery of
the valve.
Drilled Trim and Multistage Designs Figure 6.13o shows the
cross-section of three types of drilled holes that could be used
in an anticavitation cage. The thin plate design is a very
2
inefficient flow device, but it does provide a high FL value
and therefore a low pressure recovery. The thick plate design
is not only more efficient, but it also provides a high pressure
2
recovery as denoted by its low FL value.

The Cavitrol trim hole, designed by Fisher Controls, is
a balance between the thick plate and the thin plate hole
designs. It provides relatively high flow efficiency while still
2
maintaining a high FL value, which results in a low pressure
recovery. This design represents the optimal choice between
capacity and cavitation control.
Figure 6.13p shows the cross-section of a three-stage, anti-
cavitation trim. This particular design prevents the formation of
damaging cavitation at pressure drops up to 3000 psid (207 bar)
by utilizing a unique expanding flow area design, meaning that
each stage has successively larger flow area.
When a series of drilled holes are used to control cavi-
tation, it is also easy to characterize the trim. In the trim
illustrated in Figure 6.13p, as the valve plug travels through the
cage, the cage design changes. It begins as a pressure-staging
device and transitions to a straight-through, low-restriction
flow design. Consequently, the cavitation control ability of
 6.13 Miscellaneous Valve and Trim Designs 1207

P1

Equal drop through

six stages
Pressure

Inlet pressure
to final stage
Cavitrol 4
trim

P2
PV
PVC

1 2 3 4 5 6
Fluid travel through the valve stages

FIG. 6.13n
Comparison of staged pressure drops to prevent cavitation. (Courtesy of Fisher Controls.)

Thin plate Thick plate Cavitrol hole

Low CV High CV High CV
High FL2 Low FL2 High FL2

FIG. 6.13o
FIG. 6.13p
Comparing various drilled-hole-type anticavitation trim designs.
The cross-section of a three-stage anticavitation trim. (Courtesy of
(Courtesy of Fisher Controls.)
Fisher Controls.)

© 2006 by Béla Lipták

1208 Control Valve Selection and Sizing

this trim design is the greatest at low travels and decreases

as the valve plug travel increases.
In Figure 6.1y, a large number of anticavitation valve
designs are shown. One disadvantage of most anticavitation
trims is their potential for plugging. The flowing media often
contains small particulate matter (e.g., sand) that can plug
the passages, restricting or totally stopping flow through the
valve. If this potential exists, the particles must be removed
from the flow stream (e.g., by filtration), or an alternative
approach to cavitation prevention should be taken.
In situations where it is impossible to remove the partic-
ulates via filtration or separation, valve designs that can pass
the particulate and still resist cavitation and erosion should
be considered. The next paragraph describes some of the
control valves that can be considered for sludge or slurry
services.

Dirty Process Services

In Section 6.1, Figure 6.1ee shows a number of control valve

designs that can be considered for sludge and slurry services.
These applications involving entrained particulates are some
of the most challenging and can be found in all industries
where entrained particulates are present in the process stream,
which can cause extensive erosion to the valve trim and valve
body.
Often these applications also involve high pressure drops
that create the added potential for cavitation, flashing, and
excessive noise and vibration. It is important to address all
of these damage mechanisms in combination.
The most common valve selection for process streams
containing entrained particulates is a rugged valve design
utilizing erosion-resistant body materials and internal valve
body liners. This brute force approach often does not incor-
porate any method of staging the pressure drop and therefore
can cause valve and pipe vibration, if cavitating conditions
exist.
Sweep-Angle and Rotary Ball Valves Figure 6.13q is an
example of a valve that relies on “brute force” in being able to
operate under dirty service conditions. This valve was initially
designed for liquid asphalt service, but has also been successfully
applied in separator let-down and slurry let-down applications.
This valve utilizes a venturi-type throat design that
directs the fluid into the center of the valve and downstream
piping. This prevents impingement of the fluid on the valve
body and downstream piping. The expanded valve outlet
reduces the velocity of the exiting fluid, thereby reducing any
associated erosion effects. This is especially important in
applications that experience flashing or out-gassing, where
there may be some areas of high velocity.
The cylinder-guided valve plug ensures excellent control-
lability by providing plug stability, which results in better,
more controlled flow of the fluid through the valve and
reduced wear of the trim components.
FIG. 6.13q
Type 461 Sweep-Flo Valve by Fisher Controls.
For high-temperature applications, up to 1100°F (593°C),
the valve body can be specified with an extension bonnet to
reduce conduction of heat to the valve packing and the actu-
ator. Connections on the side of the bonnet are available to
flush particulate out of the extension bonnet cavity and back
into the flowstream as the valve opens.
Another brute force selection for applications with lower
pressure drops is to install a rotary ball valve. The plug in
the rotary valve should be facing towards the downstream
side of the valve body, so that the pressure drop will occur
downstream of the valve body. However, with this approach
it is important to provide either a durable downstream pipe
liner or a sacrificial pipe section.
As rugged as these sweep-angle and ball valve designs are,
they still can be exposed to conditions that cause excessive noise
and vibration. This is because the process fluid is not staged
through the valve trim in a manner that prevents the onset of
damaging cavitation and the resultant noise and vibration.
Dirty Service Trim Another valve design that is available
for dirty service applications (but not for heavy sludge, slurry
services, or particle sizes exceeding 0.5 in., because of plug-
ging) incorporates an axial flow path through a series of
restrictions. These restrictions divide the pressure drop into
stages, reducing the potential for cavitation and subsequent
noise generation. Figure 6.13r shows one axial flow multi-
stage trim design.
The dirty service trim (DST) trim eliminates damaging
cavitation and resultant noise and vibration by staging the
pressure across a properly determined number of stages. The

© 2006 by Béla Lipták


No significant
pressure drop
More than 90% of
pressure drop
Very low inlet
pressure to final
stage
FIG. 6.13r
Dirty service trim (DST) design of Fisher Controls.
number of stages selected is dependent upon the pressure
drop of the application and is designed in the same manner
as was shown in Figure 6.13n.
The higher the pressure drop, the more stages become
3 reduction strategies and reduces valve noise by up to 40 dB.
necessary. This trim design can pass particulates up to /4 in.
in diameter without plugging. The large open flow paths and
expanded area staging design also compensate for volumetric
expansion in flashing fluids, thus reducing velocities in the
trim and the downstream piping.
Also included in this DST design is a protected seat,
because the shut-off function of the trim is separate from its
throttling areas. This separation is accomplished by not allow-
ing any significant pressure drop to be taken until the fluid is
downstream of the seating surface. This type of design also
ensures that all clearance flow is subjected to a staged pressure
drop. Unlike in linear cage-style, anticavitation trim sets, here
no segment of the process flow can drop directly from the
upstream (P1) to the downstream (P2) pressure after the valve.
High Noise
Section 6.14 covers all aspects of control valve noise, and
Figures 6.14o to 6.14s show some low noise control valve
designs from a variety of suppliers.
In many cases when the process fluid remains contained
by the valve and piping, the noise generated becomes airborne
© 2006 by Béla Lipták
6.13 Miscellaneous Valve and Trim Designs 1209
FIG. 6.13s
WhisperFlo noise abatement trim by Fisher Controls.
only by its transmission through the valves and the adjacent
piping. The sound field in the flow stream forces these solid
boundaries to vibrate. These vibrations cause disturbances in
the ambient atmosphere that are propagated as sound waves.
There are several ways to eliminate excessive valve noise
(see Section 6.14), but this section will focus mainly on
source treatment methods, which are obtained through spe-
cially designed control valve trim. There are many types of
control valve trims that were designed to reduce valve noise,
but there are only two ways to accomplish this reduction.
One method is referred to as frequency shifting, while
the other is velocity control. The former approach, which has
been used for many years, incorporates small, properly sized
and spaced passages that raise the frequency of the fluid
exiting the trim. The higher frequency reduces acoustic energy
in the audible range by relying on the transmission loss of the
piping. The latter approach (velocity control) can be accom-
plished in many ways, and the highest level of noise attenu-
ation is usually accomplished by incorporating both methods.
Figure 6.13s shows the cross-section of a multistage
noise reduction trim that utilizes a combination of noise
Some of the features of this design include
• Unique passage shape reduces the conversion of total
stream power generated by the valve into noise power.
• Multistage pressure reduction divides the stream
power between stages and further reduces the acoustic
conversion efficiency.
• Frequency spectrum shifting reduces acoustic energy
in the audible range by capitalizing on the transmis-
sion loss of the piping system.
• Exit jet independence avoids noise regeneration due
to jet coalescence.
• Velocity management is accomplished with expanding
areas to accommodate the expanding gas.
• Complementary body designs avoid flow impingement
on the body wall and secondary noise sources.
As explained in detail in Section 6.14, the amount of
noise that will be generated by a control valve can be pre-
dicted quickly and reasonably by use of industry-standard
methods. In order to obtain accurate noise predictions, it is
important to utilize the standards described in Section 6.14.
1210 Control Valve Selection and Sizing
High-Capacity Valves
Globe-style valves larger than 12-in., ball valves over 24-in.,
and high-performance butterfly valves larger than 48 in. are
considered to be special valves. As valve sizes increase, shut-
off static pressure loads also increase. Consequently, shaft
strength, bearing loads, unbalance forces, and available actuator
thrusts all become more significant with increasing valve size.
Noise levels must also be carefully considered in all large-
flow installations because sound pressure levels increase in
direct proportion to the magnitude of flow. To keep valve noise
within tolerable limits, large cast or fabricated valve body
designs have been developed. These bodies, which are normally
cage-style constructions, use very long plug travel, a great num-
ber of small flow openings through the wall of the cage, and
an expanded outlet line connection to minimize noise genera-
tion and to reduce fluid velocity.
With the increase in valve plug travels, the selection of
the actuator used becomes more important. Typically, long-
stroke, double-acting pneumatic piston actuators are selected.
With these types of actuators, the accessories required to
move the actuator also become more complex.
Cryogenic Valves
Cryogenic applications are those with temperatures that
fall below –150°F (–110°C). Globe-style valves in cryogenic
services are used in both cold box applications and non-cold
box applications.
Cold boxes are commonly found in the air separation
industry. Valves used in these applications feature bodies with
welded extension necks and standard length bonnets to allow
in-place trim maintenance from outside the cold box. For
non-cold box applications, a cryogenic valve with an exten-
sion bonnet is used.
For control valves in cryogenic service, the correct selec-
tion of plastic and elastomeric components are important,
because they often cease to function properly at temperatures
below 0°F (–18°C). In these low-temperature ranges, compo-
nents such as packing and plug seals require special consid-
eration. For plug seals, a standard soft seal will become very
hard and less pliable, thus not providing the shut-off that is
required. Special elastomers have been applied in these tem-
peratures, but require special loading to achieve a tight seal.
Packing is a concern in cryogenic applications because of
the frost that may form on valves. Moisture from the atmo-
sphere condenses on surfaces where the temperature is below
freezing and will freeze into a layer of frost. As this frost and
ice forms on the bonnet and stem areas of control valves and
as the stem is stroked by the actuator, this layer of frost is
drawn through the packing, causing tears and a loss of seal.
The solution is to use an extension bonnet (Figures 6.1t,
6.1u, 6.13t, 6.19p, and 6.19q) that allows the packing box area
of the control valve to be warmed by ambient temperatures,
thus preventing frost from forming on the stem and packing
box areas. The length of the extension bonnet depends upon
© 2006 by Béla Lipták
FIG. 6.13t
The construction of a cryogenic valve with extended bonnet. (Cour-
tesy of Fisher Controls.)
the operating process temperature and on the insulation
requirements.
When testing cryogenic valves for shut-off or in hydro-
static tests, the use of water-based tests should be avoided.
If water tests are conducted, it is possible that moisture can
be trapped inside the body or extension bonnet, which could
ultimately form ice in the valve after it is cooled down. For
these types of applications, in order to prevent freezing, the
proper test medium is usually helium.
High-Temperature Valves
Valves that operate at temperatures above 450°F (232°C)
experience many of the same limitations as do cryogenic
valves. At elevated temperatures, the standard materials of
control valve construction might be inadequate. For instance,
plastics, elastomers, and standard gaskets generally prove
unsuitable and must be replaced by more durable materials.
Metal-to-metal seating materials are always used. Semime-
tallic or laminated flexible graphite packing materials are
commonly employed, and spiral-wound stainless steel and
flexible graphite gaskets are necessary.
It is important to select the trim materials and valve
designs that will not experience sticking and gasket failure
due to thermal expansion. If dissimilar trim materials are used,
it is possible that one part will react to the high temperature
faster than another, causing the components to gall. It is also
important to allow the trim to grow axially in the valve body.
Hanging the cage element from the top of the valve body does
this. Some designs also incorporate internal springs or load
rings to allow for the thermal expansion of the trim.
Similar to cryogenic applications, extension bonnets are
used to protect the packing box parts from extremely high
 6.13 Miscellaneous Valve and Trim Designs 1211

temperatures. For the selection of metallic and packing mate-

rials (Figure 6.1o) and the use of jacketed valve designs
(Figures 6.1p to 6.1r), refer to Section 6.1.

Steam Conditioning Valves

Steam conditioning applications are examples of services

where valves are exposed to high temperatures. These valves
serve the function of simultaneously reducing the steam pres-
sure and temperature to the level required for a given appli-
cation. Frequently, these applications deal with high inlet
pressures and temperatures and require significant reduction
of both. They are, therefore, best manufactured as a forged
or a fabricated body that can better withstand steam loads at
elevated pressures and temperatures.
Forged materials permit higher design stresses, improve
grain structure, and offer an inherent material integrity that
is superior to cast valve bodies. The forged construction also
allows the manufacturer to provide up to ANSI Class 4500,
as well as intermediate and special class ratings, with greater
ease vs. cast bodies. FIG. 6.13u
Due to frequent extreme changes in steam properties as The design of a steam conditioning valve, which is provided with
a result of the temperature and pressure reduction, the forged an integral cooling manifold. (Courtesy of Fisher Controls.)
and fabricated valve body design allows for the addition of
an expanded outlet to control outlet steam velocity at the
lower outlet pressure. Similarly, with reduced outlet pres- individual spray nozzles installed in the outlet section, which
sure, the forged and fabricated design allows the manufac- provide a fine spray mist that is injected radially into the
turer to provide different pressure class ratings for the inlet highly turbulent stream of flowing steam.
and outlet connections to more closely match the adjacent The combination of having a large surface area contact-
piping. ing the water and the high turbulence makes the mixing
Other advantages of combining the pressure reduction efficient and the vaporization rapid. For this control system
and desuperheating functions in the same valve versus two an external water control valve is required, which is throttled
separate devices include: by a downstream temperature controller to provide the
• Improved spraywater mixing due to the optimum uti- required fine-tuning of the temperature control.
lization of the turbulent expansion zone downstream These types of valves are most commonly used in power
of the pressure reduction element (utility, cogeneration, and industrial) plant applications,
• Improved rangeability which include the start-up of steam turbines, and the bypass-
• Ease of installation and servicing of only one device ing, dumping, venting, and exporting of steam.

The manifold steam conditioning valve design Tank-Mounted Valves

(Figure 6.13u) is the most common form of steam condition-
ing valve available. This valve design offers all of the benefits
of a combined valve, but features the ability to provide mul-
tipoint water injection utilizing an externally mounted man-
ifold around the valve outlet. With this manifold, large quan-
tities of water can be injected with a homogeneous
distribution throughout the steam outlet flow.
Positioning of the valve plug within the control cage con-
trols the steam pressure and flow. A signal from the pressure
control loop to the valve actuator moves the valve plug within
the control cage to increase or decrease the amount of free
flow area. As the plug is lifted from the seat, steam passes
into the center of the cage and out through the cage element.
The outlet section is outfitted with a water supply man-
ifold. The manifold provides cooling water to a number of
Tank-mounted control valves are commonly found in the
chemical industry. These are reverse acting (push down to
open) control valves designed for handling corrosive fluids.
The throttling element of the valve is positioned at the valve
outlet and is placed inside the receiving tank so that flow
exits directly into the vessel. In flashing applications or
those with entrained gas, the erosion potential is greatly
reduced.
Bibliography
Ball, K. E., “Final Elements: Final Frontier,” InTech, November 1986.
Carey, J. A., “Control Valve Update,” Instruments and Control Systems,
January 1981.

© 2006 by Béla Lipták

1212 Control Valve Selection and Sizing
“Control Valves—Globe, Plug, Pinch, Needle, Gate,” Measurements and
Control, February 1993.
“Control Valves, Regulators,” Measurements and Control, June 1994.
Control Valve Handbook, 4th edition, Fisher Controls, Inc., 2003.
Control Valve Sourcebook, 3rd edition, Fisher Controls, Inc., 2003.
Fernbaugh, A., “Control Valves: A Decade of Change,” Instruments and
Control Systems, January 1980.
O’Connor, J., “The Turbine Control Valve,” Instrumentation Technology,
December 1973.
© 2006 by Béla Lipták
Rahmeyer, W., “The Critical Flow Limit and Pressure Recovery Factor for
Flow Control,” InTech, November 1986.
The Sourcebook of North American valve, Actuator and Control Manu-
facturers, 6th edition, 2004, Valve Manufacturers Association of
America.
Wilson, J., “The Impact of Valve Outlet Velocity on Control Valve Noise
and Piping Systems,” Valve World, October 2001.
Wilson, J., “Tight Shutoff in Boiler Feedwater Control Valves,” Valve World,
April 2002.