Control Valve: 1. Power actuated device which modified fluid flow rate in process control system. 2.

Control valve can be described controlled variable orifice. 3. Valve closer member is connected with actuator either stem (for linear valve) and shaft (for rotary valve). Valve type: Linear Control valve Valve stem moves linearly up and down e.g. - Globe valve Used for more severe duty. Rotary control valve Valve shaft of rotary motion valve rotates without any linear motion. e.g. Ball valve, Butterfly valve Used in moderate to light duty. For same size rotary valve is smaller and lighter. For same size rotary value is economical in cost, especially line size increases. ball Valve Full bore 1/3 ball Segment Reduce amount of seal, reduce friction, and allow more precise positioning. V- Shaped groove to improve control positioning. Trim material 300 series SS.

Post guided Moving member guided by a bushing in the valve bonnet.

Cage guided Cylindrical cage between body and bonnet, below the cage is seat ring.

Unbalanced

Plug is pressure balanced with seal, plug pressure balanced.

Post guided trim is more suited for slurries and fluid contained solid. Trim material are 400, 300 series or 17-4PH SS.

Butterfly valve

Trim material Used S shaped disk for reduce flow are 400, 300 inducted torque and more precise series or 17-4PH positioning. SS. Some time nitrated or satellite hard facing. Trim material- bronze, ductile iron, 300 Series-SS Eccentric disc

Closer similar to mushroom, with offset to the shaft. Provide good control along tight shutoff, tight shutoff without the elastomeric seat seal used in butterfly and ball valve. Trim material- 300 series SS with may be clad with satellite hard facing. Fluid pressure is sealed with packing box, ring of packing and packing follower. Packing ring compressed to provide tight seal, packing ring lose some of their volume, packing spring server to accommodate volume change. Standard and Code: ASME/ANSI B 16.34-1996

Valve flanged, threaded and welding end. 1. Provide calculation for minimum wall thickness, along with temperature/ pressure rating for 40 different body materials. 2. Provide rule for hydrostatic testing. 3. Pressure rating class 150,300,400,600,900,1500,2500,4500. 4. Common body & bonnet material is Carbon steel (CS), Chrome moly steelused for high temperature, Stainless steel-used for corrosive application. 5. Connection- Flanged, butt weld, threaded end, flangeless.

ANSI/ISA-75.01.01-2002 (60534-2-1 Mod)

ISA-75.17-1989 ANSI/FCI 70-2

Flow equation for sizing control valve. 1. Provide basic formula for liquid, vapor, and two phase flows with consideration of cavitations, flushing and sonic velocity. 2. Manufacturer having flow-sizing programs to rate their valve to maximum and minimum controllable CV. Control valve Aerodynamic Noise prediction Control valve leakage standard

Valve Selection: 1: Determine flow capacity CV:

Flow of water at 60 deg F expressed in US galleon/ minutes when valve is fully open at 1 PSI pressure drop. CV= Q(Sq root Gf/ Delta P) Q= Flow rate Gf= Fluid specific gravity Delta P = pressure drop across valve. Fluid loses pressure and accelerate as it pass through reduce area, The highest velocity and lowest pressure area is called Vena Contracta. Downstream pressure recovered, the degree of pressure recovery is major element for choosing the appropriate control valve.
Inlet Pressure

Vapor pressure= P1

Outlet pressure Vapor pressure= P2

Vena contract pressure Vc

IF Vena contracta pressure VC less then Vapor pressure P1 & P2 = Fluid will vaporize.
If Vapor pressure P2 is less then outlet pressure then fluid re condensed to liquid resulting Cavitations. If Vapor pressure P1 is higher then outlet pressure then liquid flash and remain liquid /vapor mixer.

Cavitation : occurs in liquid when the fluid pressure drop below the vapor pressure and vapor pressure is below the outlet pressure. Due to high outlet pressure, sudden collapse crate localized shock that will damage valve surface. Flashing: occurs in liquid when the fluid pressure drops below the vapor pressure and vapor pressure is above the outlet pressure. The flowing mixture of liquid and vapor may cause erosion of the valve and high flow noise. Cavitation /flushing limit flow due to increased volume of liquid/ Vapor. Choked Flow: The valve maximum flow velocity occurs at vena contracta , once flow velocity become sonic, the flow is chocked and further reduction in the downstream pressure will not increase flow rate through valve.

Selection of Valve: Determine Service Condition Type of fluid Viscosity Inlet pressure Min flow Normal flow Maximum flow

Density Outlet pressure Leakage Pressure loss Fluid temperature class

Select ANSI Class

Identified correct pressure class for valve body and trim material.

Calculate valve Capacity (Cv)

1. 2. 3. 4.

Calculate Max, Mim, And Normal Cv. Identified rangeability. Identified Max Noise. Determine if any Cavitation/ flushing/ chocked case

Select Valve type

1. Linear- High rangeability/ Heavy duty/ High acceptable pressure loss 2. Rotary- Low pressure loss/ medium duty. Review leakage class

Select Trim type

1. Select Whisper trim if aerodynamic noise if high. 2. Select Cavitrol III trim- if liquid noise is high or cavitation.

-Select Valve Size. -Trim Size for Selected Cv Select trim material.

1. 2. 3. 4.

Check Shutoff option. Actuator Size Note Valve travel. Note trim group.

Select Valve material for trim size.

Select Option.

Shutoff, Packing, Positioner ,

Actuator and Accessories Type of Actuator: Pneumatic 1. Spring diaphragm style 2. Piston style Direct Acting- Spring open valve (Fail to open) Electric Used electric motor with a gear trim to rotate a threaded stem nut for linear/ rotary valves. Motor operated valve (MOV) is used where high thrust is required. Hydraulic Usually Piston style.

Force is provided though pressurized liquid More stable and less affected with fluid pressure. Higher actuating pressure.

Reverse acting Spring close the valve (Fail to close) Lower cost then other styles, low friction, low dead band. Accessories Positioners Limit switch Measure valve stem /shaft position, comparing it in the signal Adjust fore applied by actuator to maintained position of valve closure member related to the signal. Positioner is valve controller. Smart positioner provide information of actual position, supply pressure, actuator pressure, performance diagnosis. Monitor stem/ shaft position, usually fully open/Close

Pressure transducer (IP Converter) Convert electrical signal to pneumatic/ hydraulic signal

Body Material

Material Cost Carbon Steel Cost ChromiumMolybdenum Steel Cost ChromiumMolybdenum Steel Cost 304L Stainless steel Cost 304L Stainless steel Cost 317 Stainless Steel Cost Iron

ASTM NO ASTM 216 ASTM 217

Grade WCC WC-9

Temp up to 427 Deg C 593 Deg C

Pressure 142 Welded without heat treatment unto thickness 32mm 38 Replaced C-5, Better erosion, corrosion resistant, Need preheat before welding and heat treatment after welding 38 Difficult to weld, but better resistance to high temperature sulphide resistance 139 Optimum corrosion resistance 9 Grate resistance to corrosion, pitting, creep and oxidizing 15 Better resistance than 316 Inexpensive

ASTM 217

C-5

593 Deg C

ASTM -A351 ASTM- A351

CF-3 CF-8M UNSS31700

427 Deg C 815 Deg C

ASTM -A 479 ASTM-A126

815 Deg C 515 Deg C

What Different type of Packing used in Control Valve ?. The packing assembly required seal from leakage of process fluid near valve stem area. The most control valve packing can be adjusted with Nut / Bolt the general selection is. PTFE V ring Self lubricated, V shape loaded with spring, resistance to most chemical except alkali, required most finish stem Suitable for temp: -40 to + 230 deg C Not suitable for nuclear application. Laminated and filament Graphite Long life, high thermal conductivity, provides high resistance resulting to hyterisis. Suitable temp : for cryogenic to 649 deg C Lubrication not required but bonnet extended if temp exceed 427 deg C. Temperature Deg C -18- TO 90 -40 TO 232 -40 TO 232 -8 TO 260 -8 TO 315 Life Long V. Long V. Long V. Long V. Long Friction V. Low Low Low Low Moderate

Packing System Single PTFE V Ring ENVIRO-Seal PTFE ENVIRO-Seal Duplex Carbon fiber reinforced TFE ENVIRO-Seal Graphite

What type of gasket used in bonnet and flange of control valve?

Flange gasket: up to 230 deg C should PTFE/ above that spiral wound gasket or similar. Body /Bonnet Gasket: Shall be metal filler or spiral wound stain less steel gasket with non asbestos. Or Teflon filler suitable for application.

What is Seat Leakage class in Control valve? Leakage class I II III IV V Max Allowable range 0.5 % of rated Capacity 0.1 % of rated Capacity 0.01% of rated Capacity 0.005 ml/min at per inch of orifice size at one PSI delta pressure As per table Test Medium Test Procedure No test procedure Provide full closing pressure at actuator and apply pressure to up side and down side open to ATM. Provide full closing pressure at actuator and apply pressure to up side and down side open to ATM Provide full closing pressure at actuator and apply pressure to up side and down side open to ATM Applied pressure to up stream, stroke valve, applied max through pressure, allow leakage to stable and then settle. Applied pressure to up stream, stroke valve, applied max through pressure, allow leakage to stable and then settle.

Air or Water at 1052 deg C Air or Water at 1052 deg C Air or Water at 1052 deg C Water at 10-52 deg C

VI

Air/ Nitrogen

What are valve characteristics: The relationship between valve capacity and position of stem travel is called valve characteristic of control valve.

The trim design of control valve affect, how valve capacity change with valve travel. Due to valve trim design many valve is non linear, may control system is also non linear and it is compensated with valve characteristic. The percentage flow of valve is plotted against valve stem position against constant pressure drop on the valve and called inherent flow characteristic.

Linear Flow capacity increase linearly with valve stem travel.

Equal percentage Flow capacity increase exponentially with valve stem travel. Equal increment of valve travel increase equal change in valve capacity

Quick opening Provide large change in valve capacity with small change in valve stem travel.

Modified parabolic Mid way between linear and equal percentage

It provides fine tuning at low flow and linear characteristic on high flow.

Installed Control valve Characteristic

When valve installed in across pump, process, piping and when flow increases pressure drop across valve decreases, the pressure drop across valve is vary as plug moves through stem. When actual flow is plotted against valve stem is called installed characteristic. Inherent characteristic Linear Equal percentage Installed characteristic Quick opening Linear

Application of Various type of Characteristic Linear Liquid level control Compressor anti surge control Split range control Equal percentage When in doubt about which characteristic should used. When pressure drop across control valve is small as compared to system pressure drop. Pressure control application, where varying pressure drop condition exist. Quick opening Relief valve application On- off application.

Control valve operated with manual controller