Control Valve – Interview Preparation Notes
1. Basics
• Definition: A control valve regulates fluid flow by varying the size of the flow passage, directed
by a controller.
• Purpose: Maintain process variables like pressure, flow, temperature, and level within desired
limits.
• Main Parts: Valve body, Actuator (pneumatic, electric, hydraulic), Positioner, Trim (plug, seat,
stem).
2. Types of Control Valves
• Globe Valve – good throttling, common in process industries.
• Ball Valve – quick operation, high capacity, low pressure drop.
• Butterfly Valve – compact, lightweight, for large flow.
• Diaphragm Valve – corrosion resistant, slurry service.
• Rotary Valves – economical, used in high-capacity applications.
3. Actuators
• Pneumatic diaphragm – most common, simple, cost-effective.
• Piston actuators – high thrust, suitable for high-pressure service.
• Electric actuators – precise, slow but reliable where air is unavailable.
• Hydraulic actuators – used in very high thrust and fast stroking.
4. Control Valve Characteristics
• Linear – flow ∝ stem movement.
• Equal percentage – small opening = small flow, large opening = large flow (common in process
industries).
• Quick opening – large flow with small movement, used for on/off.
5. Sizing & Performance
• Cv (Flow Coefficient): Indicates valve capacity; higher Cv = higher flow.
• Valve Response: Affected by deadband, actuator design, and positioner.
• Installed gain: Relates valve action with system response.
6. Installation & Maintenance
• Install actuator vertically above body when possible.
• Ensure pipeline is clean before installation.
• Use good piping practices – correct flow direction, flange alignment, criss-cross bolt tightening.
• Flush and hydro test system before service.
• Maintenance: Reactive (after failure), Preventive (schedule-based), Predictive
(condition-based).
7. Common Issues & Diagnostics
• Air leakage – affects actuator response.
• Friction/packing issues – cause hysteresis and poor control.
• Supply pressure problems – slow or no valve movement.
• Travel deviation – indicates positioner/actuator issue.
8. Standards & Safety
• Standards: API, ASME, ISA for sizing and testing.
• Hazardous location valves follow NEC/IEC zone classifications.
• Safety Instrumented Systems (SIS) often include final control valves as shutdown devices.
■ Quick Interview Tips
• Be clear on Cv, valve characteristics, actuator types, and positioners.
• Understand installation best practices and common failures.
• Revise preventive vs predictive maintenance differences.
• Mention relevant standards (API, ASME, ISA) when asked.
