SCHOOL OF CHEMICAL ENGINEERING

EKC 493 – Chemical Engineering Lab III

EXPERIMENT: Control Valve Characteristic

(PC3)
GROUP 21

GROUP MEMBERS : MOHAMAD SYARUL BIN MOHAMAD SABRI (129090)

NUR HIDANAH BINTI ANUAR (129112)
NOOR FADZLEENA BINTI MD ZAIN (129104)

LECTURER IN CHARGE : DR SUHAIRI ABDUL SATA

TECHNICIAN IN CHARGE : EN. MUHAMMAD ARIF
DATE OF EXPERIMENT : 20 SEPTEMBER 2018

Page | 1
 CONTENT Page
Abstract 3
Methodology 3-4
Industrial Application 4-5
Objectives 5
Result 5-7
Discussion 8-10
Conclusion 10
Reference 10
Appendix 11

Page | 2
1.0 ABSTRACT
In commercial control plant, usually there will be two common type pumps, which are
small pump (PS) and big pump (PB). The other thing is to have valve with three control valves
including FCVL, FCVQ, and FCVE, which will be the aim and purpose of this study. All three valves
work differently according to its own function with respect to valve characteristic. In addition,
the value of Cv of each valves at various valve opening need to identify by using certain equation
which is the valve design equation. Therefore, it is important to identify the valve characteristic
in order to know the effect of the valve characteristic. In those three valves of FCVL, FCVE, and
FCVQ should be linear, equal percentage and quick opening characteristic.

2.0 METHODOLOGY

This experiment will lead to specify and differentiate the installed valve characteristic
of three different valve. While running the experiment, the effect of the valve characteristic with
different control on PID flow loop tuning able to identify.

In the Experiment A, small pump (PS) was used to study the installed control valve
characteristic. Certain valves and pumps can manually control to ensure the experiment can be
done properly according to the general start-up procedure. After that, the FIC controller need to
be switch the MV to 100% in manual mode. Next, the reading on the recorder FDPZR and the
pressure gauge need to be recorded. Fmax is the maximum flow rate with a fully opened valve
(MV=100%) . The MV value keep changing with 20% reduction at a time from 100% to 0% and
from 0% to 100%. The procedure same goes to the other two valves.

In the Experiment B, instead of using small pump (PS) this time around big pump (PB)
were used. The procedure is same with Experiment A. A major change need to be done was the
Fmax in Experiment A should be the same in Experiment B as well. Therefore, a valve need to
control the opening so that the Fmax will be same as in Experiment A.

Lastly, the procedure in Experiment C started with change the manual mode with automatic
mode. Then, the FIC controller was set as PB1 = 100%, Ti1 = 5 seconds and TD1 = 0 seconds. After
that, the SV value need to be vary in this case SV at 12.1 USGPM, 13.1 USGPM and 15.1 USGPM.
The response curve need to be recorded to study the pattern whether it will be too sluggish or

Page | 3
too oscillatory. The value of TD1 also changed to TD1 = 5 second and varying the SV with the
same increment value. This procedure also need to be done to all valves.

3.0 INDUSTRIAL APPLICATION

Control system is the most commonly used in industry for processing. It helps in
operating condition in the best performance as well as preventing the process variable from
becoming critical. In each process, control loop must have a final control element that works to
manipulate a process variable. Most chemical processes, a control valve is used device to
manipulate flow of material and energy in and out of process. Therefore, in selecting a suitable
valve characterization is compulsory for stable industrial process

First, control valve is used in liquid level control or any certain flow control operation
with requirement of a gain. [1] The valve with linear characteristic are the one used for the
application. Knowing that pressure drop also involve during this control, which will vary with flow
rate. Valve with inherent linear character often been used in industry if the piping system is short
and constant pressure drop for better performance.

Second application is in every hydraulic system. It support in diverse of functions in

system for example by keeping system pressures at safe condition below a required upper limit
to maintain certain part of pressure in circuit. Most of fluid power systems are designed to run
within a planned range of pressure. The range is the forces that will lead the actuators to do
required work. With proper controlling of these forces, the damage towards fluid power
components and expensive equipments can be avoided. For this situation, relief valve is the
best choice to avoid this hazard. It has safety features that will limit the maximum pressure in
system by redirecting excess oil when pressure get too high [1].

Other than that, there is temperature control valve in manufacturing industry that
helps to retain specific temperature of certain process. Mostly, it is used in exchange of heat
between the hot process fluid and a cold process fluid in heat exchanger but the process fluids
do not mix. The hot fluid passes through the shell of the exchanger while cold fluid passes
through the tube. Hot fluid move heat energy to cold fluid thus increasing the temperature.

Page | 4
The temperature controller begin control action if the temperature of cold fluid above the set
point by sending signal to temperature control valve to either open or close [2]

4.0 OBJECTIVES

Many objectives of this experiment involving the usage of small pump (PS) and big
pump (PB) are to operate and demonstrate the operation of control valve. In addition, the
major equipment, instrumentation, control infrastructure and controller able to be identified.

After that, the type of control valves also can be identified. The Cv value can be
calculated as well. Next, the lesson that have learn is to determine and study the installed
characteristics of three control valves that are installed in their respective piping system where
more pressure drop is expected at the control valve than at the rest of the pipeline system.
Finally yet importantly, the objective of the experiment is to test the effect of different control
valve characteristics on PID flow loop tuning.

5.0 RESULT

EXPERIMENT A
FCVL

F/Fmax*100 (%) against Cv/Cvmax

120.00
(F/Fmax)*100 (%)

100.00
80.00
60.00
40.00
20.00
0.00
0.00 0.20 0.40 0.60 0.80 1.00 1.20
Cv/Cvmax

Figure 5.1 Graph of (F/Fmax)*100% (%) against Cv/Cvmax using FCVL

FCVE

Page | 5
 F/Fmax*100 (%) against Cv/Cvmax
150.00

(F/Fmax)*100(%)
100.00

50.00

0.00
0.00 0.20 0.40 0.60 0.80 1.00 1.20
Cv/Cvmax

Figure 5.2 Graph of (F/Fmax)*100% (%) against Cv/Cvmax using FCVE

FCVQ

F/Fmax*100 ( %) against Cv/Cvmax

120.00
(F/Fmax)*100(%)

100.00
80.00
60.00
40.00
20.00
0.00
0.00 0.20 0.40 0.60 0.80 1.00 1.20
Cv/Cvmax

Figure 5.3 Graph of (F/Fmax)*100% (%) against Cv/Cvmax using FCV

EXPERIMENT B
FCVL

(F/Fmax)*100 (%) against Cv/Cvmax

120.00
(F/Fmax)*100 (%)

100.00
80.00
60.00
40.00
20.00
0.00
0.00 0.20 0.40 0.60 0.80 1.00 1.20
Cv/Cvmax

Figure 5.4 Graph of (F/Fmax)*100% (%) against Cv/Cvmax using FCVL

FCVE

Page | 6
 (F/Fmax)*100 (%) against Cv/Cvmax
120.00

(F/Fmax)*100 (%)
100.00
80.00
60.00
40.00
20.00
0.00
0.00 0.20 0.40 0.60 0.80 1.00 1.20
Cv/Cvmax

Figure 5.5 Graph of (F/Fmax)*100% (%) against Cv/Cvmax using FCVE

FCVQ

(F/Fmax)*(100)(%) against Cv/Cvmax

120.00
(F/Fmax)*100 (%)

100.00
80.00
60.00
40.00
20.00
0.00
0.00 0.50 1.00 1.50 2.00
Cv/Cvmax

Figure 5.6 Graph of (F/Fmax)*100% (%) against Cv/Cvmax using FCVQ

Page | 7
6.0 DISCUSSION
EXPERIMENT A & B

1.20
Cv/Cvmax against FIC Manual Ouput (%)
1.00

0.80
Cv/Cvmax

0.60

0.40

0.20

0.00
0.00 20.00 40.00 60.00 80.00 100.00 120.00
FIC Manual Ouput (%)
FCVQ FCVE FCVL

Figure 6.1 Graph of Cv/Cvmax against FIC Manual Output (%) when using PS

Cv/Cvmax against FIC Manual Ouput (%)

1.80
1.60
1.40
1.20
Cv/Cvmax

1.00
0.80
0.60
0.40
0.20
0.00
0.00 20.00 40.00 60.00 80.00 100.00 120.00

FIC Manual Ouput (%)

FCVL FCVE FCVQ

Figure 6.2 Graph of Cv/Cvmax against FIC Manual Output (%) when using PB

Page | 8
 From figure 6.1 and figure 6.2 both graph shows the graphs of Cv/Cvmax against FIC
Manual Output (%). The value of Cv values in the graph indicates the flow coefficient of each
valves and FIC Manual Ouput (%) is the opening percentage of the valve control by the controller.
There are three different trends showed on the graph from both figures. This is because; the
valve used consists of different inherent control valves flow characteristic. Each of the valves
type remain the same of its trend for the Cv/Cvmax for both small capacity pump, PS or big
capacity pump, PB.

Based on both figures 6.1 and 6.2 , FCVL value shows a propotional relationship of
Cv/Cvmax against the FIC Manual Output (%), it means the increment of flowrate through the
control valve is in a constant manner where the flowrate and pressure drop can be expected. For
FVCE, it shows the exponential in its trend where Cv/Cvmax increases also FIC Manual Output
(%) increases too. This type of control valve will shows increases in flowrate when the pressure
drop decreases. [3]

For FCVQ, the graph showed in linearly in its trend at the beginning when FIC Manual
Output (%) is below 40 for small pump and 20 for big pump. For small pump, above 40 it starts
to slow down until the pressure drop is minimum. For big pump, above 20 it starts to slow down
until the pressure drop is minimum. By looking at both trends, it shows that FCVQ is suitable for
high flowrate. [3]

EXPERIMENT C

Experiment C is carried out by using pump PB at position 1 (FCVL). Due to shortage of

time and problem encounter which is blackout during experimenting, we could only have the
data for FCVL. By comparing set 1 and set 2, set 1 with higher value of PB which is 100 % than
set 2 with PB = 70 % , the graph shows set 1 gives more proportional action and faster control
to get into steady state than in set 2. The higher the PB, the slower the control and producing
more stable response. It also makes the control performance susceptible to oscillation. For set
2 and set 3, at same PB = 70 % but different changes in set point SV shows set 3 having obvious
and large oscillatory response. This is due to large difference thus producing unstable response.

Page | 9
 For set 4 and set 5, the difference is in the value of TI where set 5 having greater
value of TI and the response at higher flow rates seems more sluggish as compared to those at
lower rates. This might due to the resistance at valve closure. However, if the TI value
decreases, it will give more integral action and faster control. The longer the integral time set,
the slower the change in output; the smaller the time, the faster the output changes. To tune
the integral time, we can adjust the longer time to shorter time.

7.0 CONCLUSION

In conclusion, the pressure drop of all three types of control valves increase as the
FIC Manual Output (%) decrease. It is the same when small capacity and big capacity pump. In
addition, an appropriate increase of Proportional Band will help to shorten the rise time.

REFERENCE

[1] Retrived from:

https://www.hydraulicspneumatics.com/200/TechZone/HydraulicValves/Article/False/6411/Te
chZone-HydraulicValves

[2] Retrived from:

https://www.instrumentationtoolbox.com/2015/11/how-temperature-control-valve-
works.html

[3] Engineering ToolBox, (2003). Control Valves and Flow Characteristics. [online] Available
at:https://www.engineeringtoolbox.com/control-valves-flow-characteristics-d_485.html
[Accessed 22 September 2018]

Page | 10
APPENDIX
CALCULATION
The data is taken from experiment A, FCVL and at 80%:
𝐹
1. 𝑥 100%
𝐹𝑚𝑎𝑥

14.63
= 𝑥100% = 88.13%
16.60
𝐷𝑃𝑣 15.12
2. = 17.50−14.7 = 5.40
𝑃𝐺𝑆−14.7
𝐹 √𝑆.𝐺 14.63 √1 𝐶𝑣 3.76
3. 𝐶𝑣 = 𝑁 = 𝑥 = 𝐶𝑣𝑚𝑎𝑥 = = 0.81
1𝐹𝑃 √𝐷𝑃𝑣 1𝑥1 √15.12 4.63

Where:
Cv : Valve sizing coefficient
F : Flowrate
S.G. : Specific Gravity which is 1.0 for water at 60°F
DPV : Pressure drop across the control valve
N1 : Numerical constant
: 1.0 if F is in USGPM and DPV is in psi
: 0.865 if F is in m3/Hr and DPV is in bar
Fp : Assume Fp = 1 if the valve body or line size is the same size as its adjoining
pipelines.
(Cvmax and Fmax occur when valve opening (Z or M) is at 100%.)

Page | 11
DATA
Experiment A
FCVL
EXPERIMENT A
FVCL
MV Flowrate (F) (%) Valve Opening (Z or m) (%) Value pressure drop (Dpv) 100% Pump discharge pressure (PGS) (psig) (F/Fmax)*100% (%) Dpv/PGS Cv Cv/Cvmax
100.00 16.60 104.78 12.86 16.50 100.00 7.14 4.63 1.00
80.00 14.63 87.50 15.12 17.50 88.13 5.40 3.76 0.81
60.00 11.91 64.72 17.50 19.00 71.75 4.07 2.85 0.61
40.00 8.45 41.20 20.48 20.50 50.90 3.53 1.87 0.40
20.00 3.78 15.00 23.18 22.50 22.77 2.97 0.79 0.17
0.00 0.00 -0.50 23.82 24.50 0.00 2.43 0.00 0.00
20.00 3.75 14.55 23.16 22.50 22.59 2.97 0.78 0.17
40.00 8.36 38.20 10.52 20.50 50.36 1.81 2.58 0.40
60.00 11.93 61.55 17.66 19.00 71.87 4.11 2.84 0.61
80.00 14.63 84.48 15.00 17.50 88.13 5.36 3.78 0.82
100.00 16.59 104.68 12.84 16.50 99.94 7.13 4.63 1.00

FCVE
FCVE
MV Flowrate (F) (%) Valve Opening (Z or m) (%) Value pressure drop (Dpv) 100% Pump discharge pressure (PGS) (psig) (F/Fmax)*100% (%) Dpv/PGS Cv Cv/Cvmax
100.00 14.53 104.28 9.22 17.5 99.59 3.29 4.79 1.00
80.00 10.24 82.68 16.16 20 70.19 3.05 2.55 0.53
60.00 4.37 59.12 22.32 22.5 29.95 2.86 0.92 0.19
40.00 1.71 34.88 24.26 23.5 11.72 2.76 0.35 0.07
20.00 0.53 10.45 22.46 24 3.63 2.42 0.11 0.02
0.00 0 -0.83 23.82 24.5 0.00 2.43 0.00 0.00
20.00 0.52 10.08 23.44 24 3.56 2.52 0.11 0.02
40.00 1.62 34.30 22.80 23.5 11.10 2.59 0.34 0.07
60.00 4.03 58.92 21.10 22.5 27.62 2.71 0.88 0.18
80.00 10.08 82.10 16.48 20 69.09 3.11 2.48 0.52
100.00 14.59 104.17 9.32 17.5 100.00 3.33 4.78 1.00

FCVQ
FCVQ
MV Flowrate (F) (%) Valve Opening (Z or m) (%) Value pressure drop (Dpv) 100% Pump discharge pressure (PGS) (psig) (F/Fmax)*100% (%) Dpv/PGS Cv Cv/Cvmax
100.00 18.79 102.50 10.18 15.00 100.00 33.93 5.89 1.00
80.00 18.72 79.75 10.20 15.00 99.63 34.00 5.86 1.00
60.00 18.55 53.83 10.44 15.00 98.72 34.80 5.74 0.97
40.00 17.93 51.85 11.72 15.50 95.42 14.65 5.24 0.89
20.00 9.95 7.47 19.20 20.00 52.95 3.62 2.27 0.39
0.00 0.00 0.00 23.78 24.00 0.00 2.56 0.00 0.00
20.00 9.73 7.25 19.38 20.00 51.78 3.66 2.21 0.38
40.00 17.44 31.50 11.78 15.50 92.82 14.73 5.08 0.86
60.00 18.55 56.60 10.49 15.50 98.72 13.11 5.73 0.97
80.00 18.72 79.30 10.18 15.50 99.63 12.73 5.87 1.00
100.00 18.74 102.37 10.18 15.50 99.73 12.73 5.87 1.00

Page | 12
Experiment B
FCVL
EXPERIMENT B
FCVL
MV Flowrate (F) (%) Valve Opening (Z or m) (%) Value pressure drop (Dpv) 100% Pump discharge pressure (PGS) (psig) (F/Fmax)*100% (%) Dpv/PGS Cv Cv/Cvmax
100.00 16.55 104.63 13.14 57.00 99.04 0.31 1.26 0.99
80.00 15.92 87.12 18.02 58.00 95.27 0.42 0.88 0.70
60.00 14.55 64.88 26.20 60.00 87.07 0.58 0.56 0.44
40.00 11.87 41.10 40.80 63.00 71.04 0.84 0.29 0.23
20.00 6.23 14.95 63.14 70.00 37.28 1.14 0.10 0.08
0.00 0.00 -0.47 76.46 78.00 0.00 1.21 0.00 0.00
20.00 6.15 14.50 61.78 70.00 36.80 1.12 0.10 0.08
40.00 11.81 38.38 41.36 63.00 70.68 0.86 0.29 0.22
60.00 14.49 61.78 26.30 60.00 86.71 0.58 0.55 0.43
80.00 15.93 84.40 17.92 58.00 95.33 0.41 0.89 0.70
100.00 16.71 104.55 13.14 57.00 100.00 0.31 1.27 1.00

FCVE
FCVE
MV Flowrate (F) (%) Valve Opening (Z or m) (%) Value pressure drop (Dpv) 100% Pump discharge pressure (PGS) (psig) (F/Fmax)*100% (%) Dpv/PGS Cv Cv/Cvmax
100.00 16.55 104.12 12.12 57.00 100.00 0.29 4.75 1.00
80.00 13.61 82.42 29.94 61.00 82.24 0.65 2.49 0.52
60.00 7.01 58.85 60.00 69.00 42.36 1.10 0.90 0.19
40.00 3.04 34.75 71.08 74.00 18.37 1.20 0.36 0.08
20.00 1.07 10.40 74.52 77.00 6.47 1.20 0.12 0.03
0.00 0.00 -0.83 76.44 79.00 0.00 1.19 0.00 0.00
20.00 1.06 10.02 74.50 77.00 6.40 1.20 0.12 0.03
40.00 2.96 34.23 69.94 74.00 17.89 1.18 0.35 0.07
60.00 7.03 58.40 60.38 69.00 42.48 1.11 0.90 0.19
80.00 13.62 81.90 30.86 61.00 82.30 0.67 2.45 0.52
100.00 16.55 104.10 12.20 57.00 100.00 0.29 4.74 1.00

FCVQ
FCVQ
MV Flowrate (F) (%) Valve Opening (Z or m) (%) Value pressure drop (Dpv) 100% Pump discharge pressure (PGS) (psig) (F/Fmax)*100% (%) Dpv/PGS Cv Cv/Cvmax
100.00 16.48 102.40 7.94 57.00 100.00 0.19 46.44 1.00
80.00 16.45 79.75 7.98 57.00 99.82 0.19 46.47 1.00
60.00 16.45 56.15 8.28 57.00 99.82 0.20 47.33 1.02
40.00 16.28 32.10 10.12 57.00 98.79 0.24 51.79 1.11
20.00 12.48 7.83 32.10 62.00 75.73 0.68 70.71 1.52
0.00 0.00 0.63 76.28 78.00 0.00 1.21 0.00 0.00
20.00 12.70 7.45 32.92 62.00 77.06 0.70 72.87 1.57
40.00 16.20 31.50 10.18 57.00 98.30 0.24 51.69 1.11
60.00 16.44 55.70 8.30 57.00 99.76 0.20 47.36 1.02
80.00 16.48 79.40 7.90 57.00 100.00 0.19 46.32 1.00
100.00 16.44 102.43 7.92 57.00 99.76 0.19 46.27 1.00

Page | 13
Experiment C

BIG PUMP - FCVL

SET 1

PB = 100 %

TI = 5 sec

TD = 0 sec

SV 12.1 13.1 15.3 13.1 12.1

MV 48.25 53.52 82.88 53.48 48.15

SET 2

Page | 14
Page | 15
PB = 70 %

TI = 5 sec

TD = 0 sec

SV 12.1 13.1 15.3 13.1 12.1 15.0 12.1

MV 48.13 54.80 82.40 52.97 48.05 76.10 48.08

SET 3

Page | 16
PB = 70 %

TI = 5 sec

TD = 0 sec

SV 12.1 15.0 12.1

MV 48.03 76.92 48.08

SET 4

Page | 17
PB = 100 %

TI = 5 sec

TD = 0 sec

SV 12.1 15.0 12.1

MV 47.98 74.90 47.93

Page | 18
SET 5

PB = 100%

TI = 10 sec

TD = 0 sec

SV 12.1 14.0 12.1

MV 47.98 60.40 47.83

Page | 19