CONTROL VALVES

 A control valve is a valve used to control fluid flow by varying the size of
the flow passage as directed by a signal from a controller.

 Control valve regulates the flow of liquid (or) gas by opening (or) closing
the internal passages. This enables direct control of flow rate and
consequential control of process quantities such as pressure, temperature
and liquid level.

AIR TO OPEN VALVE: (FAIL CLOSE)

These are normally held closed by the spring and require air pressure (a control
signal) to open them. They open progressively as the air pressure increases.
AIR TO CLOSE VALVE: (FAIL OPEN)
These are normally held open by the spring and require air pressure to move them
towards the closed position.
1. What is control valve? Why it is called variable orifice? Classify various
types of control valve?
CONTROL VALVE:
A Control valve is a valve used to control fluid flow by varying the size of the
flow passage as directed by a signal from the controller.
CONTROL VALVE CALLED AS VARIABLE ORIFICE:
The variable orifice valve is similar to the control valve as VOV creates discharge
air by automatically reducing the orifice area and low compressor speed(less air
less area) (Cold) for hot climate. The VOV opens for larger orifice area and high
pressure (more air, more area)(hot).Thus in control valve as we give air the valve
will open and valve will be close as AIR TO OPEN & AIR TO CLOSE valve.so
it is called VARIABLE ORIFICE.
Assume at extreme cases like,
 Full open – low – velocity high
 Full close – high – velocity zero.
VARIOUS TYPES OF CONTROL VALVE:
There are two basic types of control valve. They are
 Rotatory motion valve like ball, butterfly or eccentric valves.
 Linear motion valves having globe, gate, diaphragm or pinch type valves.
2. What are the various characteristics of a control valve? Draw the graphs?
Explain the characteristics using % opening (Vs) % flow rate table?
FLOW CHARACTERISTICS;
The relationship between the control valve capacity and valve stem
travel.
VARIOUS CHARACTERISTICS OF CONTROL VALVE:
The various characteristics of the control valve are
  Linear
 Equal percentage
 Quick opening
 Square root
 Modified parabolic
 Hyperbolic
GRAPH:

These curves are based on constant pressure drop across the valve and are called
inherent flow characteristics.
CHARACTERISTICS IN DETAIL:
LINEAR CHARACTERISTICS:
 The flow capacity increases linearly with the valve travel.
For example: 50% flow = 50% valve lift or travel.
 It is directly proportional.
F (l) =l
dy/dx = m (1)
EQUAL PERCENTAGE:
The flow capacity increases exponentially with valve travel. Equal
increment of valve travel produce equal percentage changes in the existing CV.
F (l) = Rl-1
 dy/dx = y dy/y =dx
Y=ex+c
QUICK OPENING:
 The larger changes in flow for very small changes in lift.
 It is used for larger flow needs.
For example: 40% valve lift = 90% flow rate

F (l) = √𝒍
 It is similar to the square root and hyperbolic characteristics.

MODIFIED PARABOLIC:
 The midway between linear and equal percentage.
 It provides fine throttling and low flow capacity (equal %) and linear at
high flow capacity.
1. What is overall CV of control valve when connected in series?

In general, when connected in series

𝟏 𝟏 𝟏
= +
(𝑪𝑽𝒕) √(𝑪𝑽𝟏) √(𝑪𝑽𝟐)
Here,
CVt = Total flow coefficient
CV1 = flow coefficient 1
CV2 =flow coefficient 2
Then,
CVt = 10+20 = 30
CV1= 10
CV2 =2
𝟏 𝟏 𝟏
= +
√𝟑𝟎 √𝟏𝟎 √𝟐𝟎
𝟏 𝟏 𝟏
= +
𝟔𝟎𝟎 𝟏𝟎𝟎 𝟒𝟎𝟎
𝟏 𝟓
=
𝟔𝟎𝟎 𝟒𝟎𝟎

Overall CV = 7.5
4. What is overall CV when connected in parallel?

In general, when connected in parallel

CVt =CV1 + CV2
CVt = 10+20
CVt = 30
5. What is the definition of CV? Why it is so important?
DEFINITION:
 CV is the capacity of the valve to deliver flow with and available
differential pressure across the valve.
 CV by definition is the number of gallons per minute (GPM) a valve will
flow with a 1 psi pressure drop across the valve.
𝑮𝑷𝑴
CV =
√∆𝑷

WHY IT IS SO IMPORTANT:
The CV (flow coefficient) of a valve is much more important because, each valve
specification of a CV value, the flow with differential pressure that is less than
specified considered as oversized and if flow with differential pressure that is
greater than specified considered as undersized.so for, each valve the range of
flow to be sent depends only on CV of the valve.so it is more important.
 OVERSIZED: Cause hunting, poor control &premature actuator wear due
to excessive cycling.
 UNDERSIZED: May not be able to provide enough flow to meet the
specification.
6. What is an Actuator? What are the various types of actuator? What are
the various parts in actuator?
DEFINITION:
The actuator is the mechanism for opening and closing a valve. The actuator
accepts the signal from the control system and in response, moves the valve fully
open (or) fully close (depending on whether ON/OFF (or) continuous control
action is used).
TYPES OF ACTUATOR:
The various types of the actuator are,
 Manual
 Pneumatic
 Hydraulic
 Electric

VARIOUS PARTS OF ACTUATOR:

The various parts of the actuator are,
 Rain cap
 Eye bolt
 Diaphragm
 Spring
 Actuator stem
 Diaphragm case
 Scale plate
 Stem connector
 Yoke
7. What is valve body? What are various parts of valve body? Which part
do you feel is very important?
DEFINITION:
A valve body is a device that regulates directs (or) controls the flow of fluid
(gases, solid, liquid) by opening &closing or partially obstructing various
passageways.
VARIOUS PARTS IN VALVE BODY:
 Bonnet
 Stud bolt &nut
 Packing flange
 Packing follower
 Gland packing
 Valve plug
 Gasket
 Guide ring
 Guide bushing
 seat ring
 Seal ring

IMPORTANT PART IN VALVE BODY:

 Valve bonnet
 Valve trim (disk .seat, stem, plug)
 Cage, seat ring, seal ring
 Body gasket (or) bonnet gasket
 Seat gasket
8. What is Lapping? Why do you do machining of seat and plug?
DEFINITION:
Lapping is a machining process in which two surfaces are rubbed together with
an abrasive between them, by hand movement or using a machine.
MACHINING OF SEAT AND PLUG:
We are doing the machining of seat and plug to arrest the leakage. If it is not
possible with lapping we will go for machining.
9. What is leakage in a valve? Which class has more leakage? How do we
check whether the valve is leaking (or) not?
LEAKAGE IN A VALVE:
 The valve leakage refers to f through a valve which is set in OFF state.
 The valve leakage depends on what valve is controlling.
MORE LEAKAGE CLASS:
Among the certain classes of leakage the CLASS 2 has more leakage when tested
(0.5% with 50 Psi)
HOW TO CHECK VALVE IS LEAKING OR NOT:
 The valve leakage is tested, using either a hydrostatic test (i.e.) liquid or
pneumatic test (i.e.) gas.
 Zero leakage is rare if ever possible, so the standards define the maximum
allowable leakage under specified testing conditions.
𝑲𝑮
ANSI B 16 104 (AIR) → ∆𝑷 → 𝟑𝟓 𝑰𝑵𝑳𝑬𝑻 → 𝑹𝑶𝑻𝑨𝑴𝑬𝑻𝑬𝑹
𝑪𝑴𝟐

10. What is shell test? At what pressure rating you do shell test?
DEFINITION:
 The shell test (body test) is used to check whether there is leakage in valve
is there or not.
 The valve is mounted on the test bench and shall be partially open .the
valve body is subjected to hydrostatic test.
 The result is satisfactory when there is no leak observed from valve body,
packing gland etc. no leakage is acceptable. The pressure shall not be
dropped during the test.
PRESSURE RATING DURING SHELL TEST:
Based on the certain standards API standard generally, shell test not less than 1.5
times the 38 deg C (100 deg F) pressure rating, rounded off to the next higher 1
bar (25 psi) increment.
At 300#
Room temperature = pressure 1
 100-200 = pressure 2
200-300 = pressure 3
11. What is gland test?
 In the hydrostatic test comprises of shell test and gland test.
 The gland test is nothing but leakage in the actuator parts except the valve
body.
 In the AIR TO CLOSE control valve for checking the gland leak, the flange
is fitted on both side of the body and remove the air supply. By supplying
the water at the pressure of 20kg to 30 kg when it is 150 rating and 52kg
for 300rating.
 In the AIR TO OPEN control valve the flange is fitted on both side of the
body with air supply and certain kg of pressure of water supply depends on
the control valve. By supplying air and 52 kg of pressure of water the
leakage will be checked by the process.

12. What is seal ring, seat ring, and cage in valve body?
SEAL RING: (IN PLUG)
 Valve seals have an impact and main functions of valves, which are to
control flow and prevent leakage. Valve seal prevent to escape liquid (or)
gaseous media.
 Seals, sealing rings, O-rings (or) gaskets are required between the bonnet
and valve body.
 Certain valves have a seal material between the plug and seat (or) seat and
body.
SEAT RING: (IN CAGE VALVES)
 The valve seat is a surface inside the body of a valve that comes in contact
with disk, which is a movable component that restricts and allows flow
through the valve.
 The valve seat ring creates a shutoff surface held in place by pressure, a
seat ring may also be threaded and screwed into valve body.
 The seat ring is a crucial part for maintaining the strength of the seal within
the valve.
CAGE:
  The cage in control valve provides exceptional stability to the plug even at
very high differential pressure which eliminated vibration that could
otherwise damage the valve.
 The cage is used because to eliminate the cavitation and flashing.
 This cage will change the control valve characteristics.
13. What is vapour pressure? What is cavitation and flashing? Which is
more harmful phenomenon? How to eliminate cavitation and flashing?
VAPOUR PRESSURE:
The vapour pressure is defined as pressure exerted by a vapour in thermodynamic
equilibrium with its (solid (or) liquid) phases at a given temperature in closed
system.

CAVITATION:
 If the fluid (or) liquid pressure falls below the liquid vapour pressure, the
bubbles will form and start to explode (broken).
 These leads to cavitation which causes more sound and damages to the
control valve.
FLASHING:
This is same as cavitation as the liquid pressure is lower than the liquid vapour
pressure the bubbles will form but it will not explode.
WHICH IS MORE HARMFUL PHENOMENON:
The CAVITATION is more harmful phenomenon when compared to flashing as
the bubbles will start to explode and more noise and more damage to control
valve.
ELIMINATE CAVITATION AND FLASHING:
 Put the valve in high pressure area. This will increase the differential
pressure between the fluid pressure and vapour pressure making it less the
fluid pressure will fall low enough for flashing to occur.
 Introduce a non-condensable gas into the flow stream. For processes than
can tolerate a gas, this can prevent violent collapse of bubbles that causes
corrosion leads to cavitation.

14. What is ON/OFF valve, butterfly valve and eccentric V-plug valve?
ON/OFF VALVE:
 An ON-OFF valve is a fluid equivalent of an electrical switch, a device that
either allows flow (or) prevent flow.
 These valves are often used for routing process fluid to different locations,
starting and stopping batch processes and engaging automated safety
(shutdown) functions.
BUTTERFLY VALVES:
A butterfly valve is a valve that isolates (or) regulates the flow of a fluid. The
closing mechanism is a disk that rotates.
ECCENTRIC V-PLUG VALVE:
 Eccentric V-plug valves can be used for wide range of flow control and
isolation application including clean and dirty water.
 The eccentric V-plug valve can be used to isolate and regulate any of these
services bi-directionally.
POSITIONER:
A valve positioner is a device used to increase or decrease the air load pressure
driving the actuator until the valves stem reaches a POSITION balanced to the
output signal from the process variable instrument controller.
TYPES OF POSITIONER:
  Mechanical positioner
 Digital positioner
 Electromagnetic positioner
PARTS OF POSITIONER:
 Cam
 Cam roller
 Zero adjustment
 Span
 Scale
 Manifold
 Rubber gasket