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CONTROL

VALVES
CONTROL VALVES??
• Like a domestic water tap; but
sophisticated
• Used to adjust
flow of fluids
going through it
The ISA (Instrument
Society of America) defines
a control valve as a power
operated device that
modulates the fluid flow rate
in a process control system.
The control valve
regulates the rate of
fluid flow as the
position of the valve
plug or disk is changed
by force from the
actuator.
A valve with a power positioning
for moving to closure member
to any position relative to valve
port or ports in response to
and in proportion to an external
signal. The energy for a control
valve actuator is derived from
a independent source.
Regulator/ Control Valves operate
on a very simply equation.
SUPPLY = DEMAND
The PCV/ regulator solves this
equation by maintaining the outlet
pressure at the set point. Too much
supply or flow through the
regulator causes an increase in
downstream pressure while too
little supply results in a decrease in
downstream pressure.
ELEMENTS REQUIRED FOR
PRESSURE CONTROL
There are three essential
elements of every control
valve:
• Restricting element
• Measuring element
• Loading element
RESTRICTING
ELEMENT
The restricting element is also
referred to as the final control
element. It is the physical
restriction in the gas stream
that provides a variable
restriction that will modulate
the flow of gas through the
control valve to provide a
desired downstream pressure.
The restricting element is
usually a disk or plug.
MEASURING
ELEMENT
• The measuring element is the
brain of pressure control.
• It senses downstream pressure
and balances the restricting
element and the loading
element to achieve the desired
downstream pressure. The
measuring element is generally
a diaphragm or bourdon tube.
LOADING ELEMENT

The loading element provides the


power to position the restricting
element in the process stream.
The loading element functions to
counterbalance downstream
pressure.
The amount of imbalance
between the loading
element and the measuring
element determines the
position of the restricting
element.
Loading
Element

Measuring
Element

Restricting
Element
CONTROL VALVE
ASSEMBLY
CONTROL VALVE
STYLES
SLIDING STEM VALVES

GLOBE

ANGLE

3-WAY

STEAM CONDITIONING VALVES &


OTHER SPECIALS
GLOBE
3-WAY
ROTARY VALVES

BALL VALVES

BUTTERFLY

ECCENTRIC PLUG (E-PLUG)


CONTROL VALVE
COMPONENTS
Bonnet Yoke Lock
Nut

Plug

Stem

Cage

Seat Ring
A pneumatic,
hydraulic, or
electrically
powered device
that supplies
force and
motion to open
or close a
valve.
ACTUATOR
Bonnet
Valve Body
VALVE BODY

The part of control valve in


which the flowing medium is
contained.
The Valve Body is the main fluid
boundary and pressure
containing component. The valve
body includes provision for
securing internal parts, end
connections that allow
installation in the pipe line and a
means for attaching the bonnet.
VALVE BONNET

Major pressure containing


component and fluid boundary.
The bonnet locates and guide the
valve stem, includes a bore for
the packing referred as Packing
Box and provide means for
mounting an actuator
CLOSURE MEMBER OR PLUG

The movable part of the valve


that is positioned in the flow
path to modify the rate of flow
through the valve.
• The moveable
part of the
valve that
makes contact
with the valve
seat when the
valve is closed,
and which
varies the area
controlling the
flow
VALVE PLUG
CONTROL VALVE
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.
Trim consists of all parts of a
valve that are in contact with
the flowing medium but are
not part of the valve shell or
casting. Thus, plugs, seats,
discs, stems, packing rings,
etc. are all trim components.
Bonnet Yoke Lock
Nut

Plug

Stem

Cage

Seat Ring
TRIM MATERIAL

The effect of Wear, Galling,


Erosion and Corrosion are more
pronounced on Valve Trim, thus
selection of trim material is
vital for the stable operation
of Control Valve.
Standard Trim Material is 316 SS.

High Alloy Grades 416 SS &


17-4 PH have a proven history in
severe service application.

Valves in Flashing, Cavitations and


High Pressure applications should
be at least of 38 Rc hardness.
(Rockwell Hard ness).
COMPONENT MATERIAL

CAGE 17-4 PH

SEAT RING 416 SS

PLUG 416 SS

STEM 316 SS
HARDNESS OF TRIM MATERIAL
VALVE PLUG
GUIDING METHODS
Valve Plugs are exposed to large
fluid reaction forces that results
from fluid velocity and pressure
drop. Fluid reaction forces can
produce significant lateral (Side
ways) forces on the valve plug and
stem. In order to stabilize the
valve plug, various plug guiding
methods are used in valve designs.
CAGE GUIDED VALVES
The cage provides a massive
guiding area that aligns and
controls the valve plug
throughout the entire travel
range.
Massive guiding helps to achieve
high pressure drop application.
Cage guiding results in even
flow distribution around the
valve plug which balances side
loads and helps keep the plug in
alignment throughout entire
travel range.
Cage guiding can also provide
extended control valve life in
many application.
Valve plug is rigidly guided,
the plug seals against the
seat ring without damaging
sideways dislocation,
chattering and vibration.
Incompatible fluid like
sulphur compounds / abrasive
components cause distortion
of seal rings which results in
development of leakage path
around the seal rings
Because of their superior
stability, Cage –guided valves
provide greater Range ability
than do their Post guided
counter parts. Further their
large port area allows greater
flow capacity compared with
post guided valves.
POST GUIDING
Some Post guided valves make
include a Cage like component
referred to as a “SEAT RING
RETAINER” that serves the
following roles.
• Hold the guide bushing that guides
the valve plug.
• Retains the Seat Ring
Transmit the bonnet bolting
forces to the seat ring for
purpose of SEAT RING
retention and gasket
compression.

Seat Ring retainer does not


characterize flow.
This guiding method
results in excellent
valve plug stability and a
flow geometry that is
compatible with thick,
erosive or stick fluids.
APPLICATION GUIDE
LINES
(CAGE GUIDED VALVES)
• Suitable for clean liquids and
gases
– NOT recommended for fluids
with suspended particles as
particles can trap between
plug & cage clearance and
cause stickiness
– Also NOT suitable for
viscous liquids
• Full pressure drop capability
in flowing and shut-off
conditions
• Balanced plugs use piston
rings (or) seal rings in their
plugs to seal off leak path
between the cage and plug
– Seal materials determine
temperature limit
Noise reduction and Anti-
Cavitations features are
achieved by special cage designs

Flow direction: Up or Down


depending on cage type and
application
APPLICATION
GUIDE LINES
(POST GUIDED VALVES)
UNBALANCED PLUG
PLUG SIZE LIMITED TO 4”
DUE TO ACTUATOR
AVAILABILITY

NOISE REDUCING
FLOW
(OR) ANTI-
DIRECTION:
CAVITATION
ALWAYS
TRIMS NOT
UP
AVAILABLE
• Suitable for all types of
liquids and gases
• Ideal for viscous liquids
• Full pressure drop capability
for shut-off
• Lower pressure drop
capability for flowing
conditions
SEAT RING
RETENTION METHODS
• SCREWED IN SEAT RING
• CAGE RETAINED (OR CLAMPED)
SEAT RING
SCREWED IN SEAT
RING
SCREWED IN SEAT RING

Economical Design
Tend to work loose and allow
leakage, and said leakage
results in high velocity streams
that can quickly erode the seat
ring and body.
In corrosive application, said
arrangement have been known
to seize in the body , making
removal difficult or impossible

Not suited for high temperature


application
CAGE RETAINED
SEAT RING
Seat Ring Retainer
Guide Bushing

Seat Ring Valve Plug


The force to retain the seat ring
comes from the bonnet bolting. This
loading force is transmitted through
the bonnet gaskets , cage and seat
ring gasket to the seat ring.

At high temperature, the seat


ring will not work loose.
At high pressure drop, seat ring
gasket will not leak.

Gasket loading and seat ring


retention is a function of
bonnet bolting stresses; thus
attention to bonnet bolting
torque values is a concern.
BALANCED & UN-
BALANCED VALVE
PLUGS
• In some situations, the
pressure drop across a valve
can be very large, thus, the
force required to open (or
close) the valve would have to
very large; to prevent the need
for large forces, valves are
available which balance the
pressure drop.
• Double ported valves will not
provide the same shut off
capability as do the single ported
types because in double ported it is
almost impossible to seat both plugs
simultaneously.
• Double-ported valves are not
recommended because of their
maintenance cost and leakage.
Seat
Rings
A balanced plug includes
holes or ports that run
through the plug and
equalize the pressure
across the top and
bottom of the plug.
ADVANTAGE

Stem forces are greatly


reduced, thus a much smaller
actuator is required for
balanced valve than for an un-
balanced valve under the same
service conditions.
DISADVANTAGE

Balancing ports introduce a


second leak path between the
plug and cage walls when the
valve is closed. This leak path is
sealed by different types of
seal rings or piston rings.
BALANCING
PORT
High pressure
Controlled
pressure
UNBALANCED VALVE
PLUG
• In Un-balanced Valve design,
there is a Pressure Unbalance
across the valve plug i-e the
higher upstream pressure
registered on the bottom of
the plug and the lower down
stream pressure registers on
the top of the plug.
The pressure unbalance
results in an upward
stem force that must
be over come by the
actuator.
ADVANTAGE

Tight Shut Off because there is


only one leakage path when the
valve is closed.
Suitability for high temperature
application (for metal to metal
seats).
DISADVANTAGE

When Un-balanced Valve Plugs


are selected for high pressure
drop application , considerable
Actuator force may be required
to move the valve plug and seat
the valve plug to achieve rated
shut off.
FLOW DIRECTION

The selection of balanced or


unbalanced plug also includes the
preferred flow direction
through the valve.
FLOW UP OR FLOW DOWN
• The preferred flow direction is
established after considering
the effect of pressure on the
valve plug when the valve is in
closed position.
• PTTO Pressure Tends to Open
• PTTC Pressure Tends to Close
The normal recommendation is
PTTO. The PTTO configuration
prevents the valve plug from
slamming into the seat ring as the
valve plug near the closed position.
in valves with unbalanced plugs,
the PTTO condition is achieved
when valve is installed in flow up
configuration
BALANCED VALVE

In valves with balanced plugs ,


PTTO condition is achieved
when valve is installed in flow
down configuration due to
following factors.
1. The effect of P2 are nearly
balanced.
2. The high pressure (P1) registers
on the annular area (doughnut
shape) area. To achieve PTTO
condition, high pressure (P1)
must register on bottom
surface of annular area and this
is require a flow down
orientation.
PACKING OPTIONS

The purpose of packing is to


create a tight seal between the
packing bore and valve stem to
prevent fluid leakage to
atmosphere.
SELECTION CRITERIA FOR
PACKING

Low
friction so Packing
Packing
that material
compatibility material
actuator
can stroke with process compatibility
fluid. with fluid
the valve.
temperature.
SPRING LOADED PTFE
PACKING ARRANGEMENTS
• Low Friction
• Chemically compatible with broad
range of fluids
• Provide tight seal
• Long cycle life
• Provide constant loading (due to
spring)
Packing Packing
Flange Follower

Packing
Rings
Spring

Packing
Box Ring

Lower
Wiper
COMPONENTS

PACKING BOX RING:

• Sits at the bottom of packing bore


and provide seat for the spring.
SPRING:
• Transmit force to packing rings
through washer.
ADAPTERS:
• Male and Female adapters form flat
surfaces on top and bottom ends of
packing rings so that packing mates
squarely with other components.
PACKING FOLLOWER:
• Compresses the spring and packing
rings as packing glands nuts are
tightened.
• Due to V-shaped
packing rings, the
spring load
PACKING forces the edges
RINGS: of rings against
the stem and
packing box bore
to form a seal.
WIPERS:
Nicks and burrs in the stem would
damage packing rings as the valve
is stroked. The valve stem must
be extremely smooth. Upper and
lower wipers help to keep
particles from entering the
packing bore
• .
PRSSURE ASSIST ACTION:
• The concave surfaces of the
packing rings always face high
pressure, therefore, process
pressure also pushes the edges of
the rings against the valve stem
and packing box bore. The
orientation of the packing rings
results in a pressure assisted seal.
PTFE PACKING LIMITATIONS.

Requires extremely smooth


(2~4 micro-inch RMS) stem
finish to seal properly. Will
leak if stem or packing
surface is damaged.
Not suitable for nuclear service
because PTFE is easily destroyed by
radiation.

Since PTFE become hard below 0F,


therefore it may not be used below
0F with standard bonnet and -50F
with an extended bonnet.
GASKETS
FLAT SHEET GASKETS:
These gaskets are used as Bonnet
gaskets and as Seat ring gaskets.
SPIRAL WOUND GASKETS:
The role of spiral wound gasket is to
flex, while maintaining a pressure
tight seal to compensate for slight
expansion and contraction of cage and
seat ring height due to thermal
gradients.
Because the spiral wound
gasket acts as a spring,
it transmit the force
that is required to
maintain a tight pressure
seal over moderate
temperature changes.
BONNET
OPTIONS
In applications where the fluid
temperature is above or below the
temperature rating of the packing
material, an Extension Bonnet may
be used.
The purpose of extension bonnet is
to increase the distance between
the process fluid and the packing ,
thereby minimizing the effect of
fluid temperature on packing
RESTRICTED-CAPACITY
CONTROL VALVE TRIM
Restricted Capacity Trim can be
used to reduce Inlet and Outlet
fluid velocities.

Restricted Capacity Trim make


it possible to select a Valve body
Larger enough for increased
future load requirements.
Over-sizing errors can be
corrected by use of restricted
capacity trim parts.

Valves can be selected for


adequate structural strength,
yet retain reasonable
travel/capacity relationship.
FACE TO FACE DIMENSION GLOBE
STYLE PCVs

VALVE SIZE CLASS 600 RTJ


DN NPS MM INCH
25 1 210 8.25
50 2 284 11.37
80 3 340 13.37
100 4 397 15.62
150 6 511 20.12
200 8 613 24.12
WHISPER-1
WHISPER-III
CONTROL VALVE
ACTUATOR
FUNCTIONS
FAIL MODE OPTIONS
SPRING & DIAPHRAGM
ACTUATORS
• An increase in
diaphragm pressure
DIRECT will cause the
ACTING actuator stem to move
toward the control
valve.
• An increase in
diaphragm pressure
REVERSE will cause the
ACTING actuator stem to move
away the control
valve.
DIRECT ACTING
SPRING & DIAPHRAGM
ACTUATOR
As the diaphragm pressure is
increased, the actuator stem
extend towards the control
Valve body and spring is
compressed. As the diaphragm
pressure is reduced, the force
of the compressed spring
pushes the stem away from the
valve body.
ACT 30 34 40 45 46 50 60 70
SIZE
EFF 46 69 69 105 156 105 156 220
AREA
YOKE 2- 2- 2- 2- 2- 3- 3- 3-
BOSS 1/8 1/8 13/16 13/16 13/16 9/16 9/16 9/16

MAX 0.75 1.125 1.5 2.0 2.0 2.0 2.0 3.0


TRAVEL
CASING 125 65 65 50 40 50 40 55
PRESS

STEM 3/8 3/8 1/2 1/2 1/2 3/4 3/4 3/4


DIA
REVERSE ACTING
SPRING & DIAPHRAGM
ACTUATOR
As the diaphragm pressure is
increased, the actuator stem
extend away the control Valve
body and spring is compressed.
As the diaphragm pressure is
reduced, the force of the
compressed spring pushes the
stem towards the valve body.
SELECTING FAIL
MODE
The Fail mode of a Control Valve
Assembly depends upon followings
• The action of Actuator i-e
DIRECT ACTING OR
REVERSE ACTING
• The action of Control Valve i-e
PUSH DOWN TO OPEN OR
PUSH DOWN TO CLOSE
DIRECT ACTING BODY
(PUSH DOWN TO CLOSE)
MODELS: ED, ES, ET, EWD,
EWS, EWT
REVERSE ACTING BODY
(PUSH DOWN TO OPEN)
MODELS: EDR, ESR, ETR
DESIRED VALVE ACTUATOR
FAIL MODE ACTION ACTION

FAIL PDTC REVERSE


CLOSED
PDTO DIRECT

FAIL PDTC DIRECT


OPEN
PDTO REVERSE
BENCH SET
CONCEPTS
DEFINITION

Bench-Set is an Actuator
specification that describe the Air-
to- Diaphragm pressure range that is
required to compress the spring a
distance that is equal to the rated
valve travel when the actuator is
disconnected from all Control Valve
Forces.
In Spring & Diaphragm
Actuator, some amount of initial
compression is wound into the
spring. Generally an initial spring
force is equal to either 03 or 06
PSIG times the area of the
diaphragm.
As the diaphragm pressure
is increased from 0 PSIG ,
there will no actuator stem
movement until diaphragm
overcome the force of
initial compression.
ACTUATOR WITH
VALVE CONNECTED

When the Actuator is connected


to the Valve, the valve plug seat
serves as lower travel stop
(PDTC Valves). Rated valve travel
is typically less than the rated
Valve Travel.
FRICTION EFFECTS
Friction associated with the Packing &
other Valve components can introduce
Dead Band into Control Valve Assembly.
Dead Band is the range of diaphragm
pressure over which there is no change
in Valve stem travel. Dead Band is
observed as the diaphragm pressure
changes from an increasing pressure to a
decreasing pressure and vice versa.
CONTROLLER
The following are the key
Components of a controller
1. Sensing Element
2. Proportional Element (Gain)
3. Reset Action (Integral)
4. Rate Action (Derivative)
5. Instrument Supply System
SENSING ELEMENT
The sensing element is the
measuring device that
constantly monitors the
downstream pressure. It usually
consists of a bourdon tube,
capsular element or a helical
coil. Proper selection of the
pressure range of the sensing
element is essential.
• The normal operating pressure
of the process should be the
mid-point of the sensing
element’s pressure range.
Accuracy of the sensing
element is achieved by keeping
the process within 30% to 80%
of the element’s range.
PROPORTIONAL ELEMENT
(GAIN)
• The proportional element adjusts its
control action in proportion to the
need of the process. It senses the
deviation from the set point and
sends an output signal that is
proportional to the amount of
deviation.
The gain element is usually a
flapper and nozzle assembly. The
flapper controls the amount of
bleed out of the nozzle, thus
controlling the output pressure to
the actuator and maintaining the
established set point.
• The goal is to set the
proportional band as low as
possible while maintaining
stability throughout the control
range. “Proportional Only”
controllers experience the
same droop effects as a
conventional regulator.
RESET ACTION
(INTEGRAL)
The function of the
reset element is to
smooth out the
proportional offset
error and bring the
system process back
to the set point.
• The reset assembly utilizes a
series of small corrections to
correct the difference between
the offset and the set point
bringing the control pressure back
to the set point.
• The reset action is expressed in
“minutes per repeat” or “repeats
per minute”.
RATE ACTION
(DERIVATIVE)
The rate element performs the
same function as the reset
element. It is designed to
eliminate the droop from the
system by providing small
corrections to achieve the
established set point. The
difference is the rate element
is a function of time as
opposed to the magnitude of
error.
• The rate element increases
the speed in which the
process is returned to the set
point.
• Most controllers used in the
natural gas industry utilize
only the proportional and
reset elements
PCVs
DAMAGES
TO BELIEVE THAT FLUID
IS CLEAN IS WISHFUL
THINKING

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