Control Valves

By
Aftab Ahmed Mazari

Control Valve
Control

Valve plays a very important part in

industries.
It

controls and distributes pressure, flow,

level, temperature etc.

Control

valve may be considered the

MUSCLE of automatic control.

Types of Valves
Gate

Valve

Globe
Plug

Valve

Valve

Butterfly

Valve

Diaphragm Valve

Major Parts of a control Valve

A control

valve consists of two major

sub-assemblies.
A valve body sub-assembly
An actuator.

The

valve body sub-assembly is the portion

that actually controls the passing fluid.
It consists:
Housing
Internal trim
Bonnet

Types of Valve Bodies

Globe

Styles

The most common control valve body style is

in the form of a globe.
Such a control valve body can be either single
or double-seated.
Single-seated valves, are usually employed
when tight shut-off is required.
Tight shut-off in this case usually means that
the maximum expected leakage is less than
0.01% of the maximum valve CV

Single Seated Valves

Single-seated

valves usually have a top

guided construction.
It

also allows a somewhat higher flow

capacity than top and bottom guided valves

for a given orifice size.

Double-seated value
A

double-seated value, is generally top and

bottom guided.

Leakage

figure approaches 0.5% of the rated

CV.
It

is nearly impossible to close the two ports

simultaneously

Advantage

of double-seated construction
lies in the reduction of required actuator
forces.

Angle Valves
These
Used

Valves are single-seated.

for high pressure drop service.

Minimum Space required.

Cage Valves
So-called

"top entry" or cage valves have

the advantage of easy trim removal.

Typical

top entry valve with unbalanced,

single-seated trim.

The

inner valve parts, often referred to as

"quick change trim," can easily be removed
after removing the bonnet, because of the
absence of internal threads.

Rotary Types of Control Valves

Advantages

Low weight
Simple design
High relative CV
More reliable
Friction-free packing
Low initial cost.

Rotary Types of Control Valves

Disadvantage

Generally not suitable below 1 to 2 inches.

Operating shaft must be designed to support a
fairly heavy side-thrust.
Leakage problem.

Butterfly Valves
The

most common type of rotary valve

used for control is the butterfly valve.

The

typical application range is in sizes

from 2 inches through 36 inches or larger,

for low or moderate pressures.
Leakage

0.5% of rated CV.

Valve Bonnets
The

valve bonnet or top closure is the

removable upper portion of the valve body
sub-assembly and is normally connected to
the body by high strength bolting.

It

is a pressure-carrying part and is,

therefore, subject to the same design
requirements as the valve housing.

Removal

of the valve bonnet generally

provides access to the valve trim.

Valve Bonnets
Some

low-pressure valves, particularly in

sizes below 2 inches, have a threaded

bonnet

connection

which

is

more

economical than a flanged joint.

The

upper portion of the bonnet contains

the valve packing.

Valve Body
Bonnet

Valve Body

Valve Body

Packing Box Assembly

The

purpose of the packing box assembly is

to contain an elastic means for preventing
the leakage of a process fluid.

Suitable

adjustments should be provided for

varying the compression of the packing
material against the surface of the stem.

The

ideal packing material should be elastic

and easily de formable.

Packing Box Assembly

In

addition, the packing should be as

chemically inert as possible

Should

be able to withstand high pressures

and high temperatures.

Selection

must be made from a variety of

materials to suit the specific service
conditions.

Packing Box Assembly

The

assembly consists of a:-

Packing flange
Packing follower (Bush)
Lantern ring
A number of equally spaced packing rings.
The lantern ring provides a space for the
insertion of lubricating grease though an
isolating valve.

Packing Material
Teflon

(PTFE)

Graphite
Grafoil
Asbestos
Teflon

(Now a days it is not being used)

Cord

Graphite

cord

Packing Material
To make
Special

rings

Tool or

With

the help of a Electrician knife

How

to cut and paste the rings

Inert Gas as a Packing

Another

approach is to pressurize the area

between the two packing with inert gas at a
pressure level, slightly higher than the fluid
pressure inside the valve.

In

this case, the inert gas might leak into the

valve, but no fluid is allowed to leak by the
stem.

This

packing arrangement is more reliable.

Very

Expensive

Teflon
The

most popular valve packing material is

Teflon.
Because of its excellent chemical inertness
and its good lubricating properties.
Teflon can be used in solid-molded or
turned form (rings).
Solid rings should be spring-loaded to
provide a minimum initial pressure against
the stem.
It can be used below 250C.

Braided Asbestos
Braided

asbestos is still a popular packing

material (even prohibited to use).

It

can be made as split rings.

Which

can be wrapped around the valve

stem.
This

type of packing usually used with mica

or graphite, particularly in high temperature
service.

Grafoil
A recent

addition to the list of available

packing materials is Grafoil.

Grafoil

is an all-graphite product that is

flexible and has direction-dependent
properties.

It

is essentially, chemically inert, except

when strong oxidizers are handled.

Valve Trim
Main

Items:

Plug
Seat Ring
Stem
Cage
Guide Bushing
Stuffing Box

Plug
Types
Types

depends upon flow characteristic:

Quick Opening
Linear
Parabolic or Equal Percentage

Plug / Seat
Direct Action

Single Seated

Reverse Action
Direct Action

Single Seated

Double-Seated

Reverse Action

Double-Seated

Plug
Contoured

Plug

Top Guided
Shape of the plug
Flat Quick Opening
A bit Conical Linear
Tapered but not conical Equal Percentage

Plug Linear

Plug Equal Percentage

Plug Quick Opening

Different Shapes of Plugs

Characteristics of Different Plugs

Valve

Opening 30 %

Quick Opening

CV 62

Linear

CV 30

Equal %

CV 8

V-Port

CV 6

Characteristics of Different Plugs

Valve

Opening 70 %

Quick Opening

CV 90

Linear

CV 70

Equal %

CV 33

V-Port

CV 30

Characteristics of Different Plugs

Valve

Opening 100 %

Quick Opening CV 100

Linear

CV 100

Equal %

CV 100

V-Port

CV 100

Valve Body

Plug & Cage

Complete Control Valve

Actuator
Diaphragm
Spring
Yoke
Indicator
Coupling Assembly

Complete Control Valve

Stem
Bush
Check

Nut of yoke

Packing
Bonnet
Body

Box

Complete Control Valve

Plug
Seat

Ring

Cage
Gaskets
Bottom

Guide

Plug
Types

Contoured Plug
Single Port
Double Port
Different Shapes

V- Port
Single Port
Double Port
Multi-v-port plug
Reduces noise

Contoured Plug

Contoured Plug

Contoured Plug

Plug
Disc

Single Port
Double Port
Mixed

Type

(Used to reduced the dynamic unbalance fluid

forces)
Balanced

Plug

Disc Type Plugs

Butterfly Disc
Butterfly

Very simple construction

High Capacity with Low Pressure
Leakage Class III

Butterfly Valve

Butterfly

V Port Plug

Ball Valve
These Valves offer the advantages
Highest Flow Capacity
Low Operating Force
Tight Shut Off

Ball Valve

Ball Valve

Ball Valve

Plug
Material

CS Carbon Steel
SS Stainless Steel
410 SS
440-C SS
316
304
17-4 PH

To improve Hardness
Stellite

Seat Ring
Just

like a Washer

Same

material as Plug

With Threads
Alignment

Face to Face
Stellite

/ Without Threads

Seat Ring

Alignment

Alignment

Cage
A bit

less hard material

But according to the requirement of process
Guides the Plug
Reduces the noise (10 to 15 db)
Quick Opening
Linear
Equal Percentage
Slotted Cage

Quick Opening

Linear

Equal Percentage

Different shape of Cages

Different shape of Cages

Different shape of Cages

Sealing Arrangement
2nd

Major leakage between plug and cage

Back

up Rings

Material

Graphite
Very Careful Brittle

Teflon (PTFE)

Gaskets
Seat

Ring Gasket

Upper
Body

Cage

Gasket

Material

Graphite / Grafoil
Asbestos
Neoprene

Actuators
Diaphragm
Piston
Direct Action
Reverse Action

Diaphragm
Direct Action
Reverse Action
Flexible

material

Rubber
Neoprene
With Enforced material Fiberglass, cotton,
nylon

Direct Action Diaphragm

Reverse Action

Diaphragm
Size

of actuator depends upon

Valve size
Process pressures
Large

size

Un-necessary expensive
Delay
Under

size

Might be impossible to open or close the valve 100 %.

Diaphragm

casings
Diaphragm Plate
O rings

Piston Actuators
Piston Actuator
For

Cylinder Actuator

high pressure

Large

diameter of pipe line

Single Acting
Double

acting

with spring

Range Spring
Diaphragm
Bench

size

Set

3 to 15 PSI
6 to 21 PSI
6 to 30 PSI

Yoke
Linkage

between actuator and valve body

Usually

self aligned but needed very

carefully to install.

Tag,

Name plate

All data about actuator

Supply Pressure
Bench set
Air to open or air to close

Yoke

Working of Control Valve

Simple

Valve

Without
Bench
No

Positioner

Set 3 to 15 PSI

air supply needed

Only

I/P or controller out put 3 to 15 PSI

will operate the Valve.

Direct Action

Control Valve without Positioner

Positioner
Main

function

Just like a controller

To cover bench set
Quick Response

Positioner
In

put

3 to 15 PSI
Out

Put

3 to 15 PSI
6 to 21 PSI
6 to 30 PSI
Depends upon Bench Set of the valve

Application of Positioner
Common Applications

To increase the control valve speed.

To operate spring-less actuators
Split range operation
Reverse action
To change the control valve flow characteristics
Nature of flow medium
For jam type process

Application of Positioner
Limitations

Adding in the loop a controlling device

Loop must have minimum devices

Expensive
Can be achieved better results with the help of
Volume booster
Pressure booster

Types of Positioners
Side
Top

mounted
mounted

Double

acting Positioner

Electronic

Control Valve With Positioner

Valve with Positioner

Valve With Positioner

Positioner

Control Valve with Positioner

Control Valve with Positioner

Cams
Linear
Equal

Percentage

Quick

Opening

Cams

Cams

Cams

Cams

Volume Booster / Pressure Booster

Volume

booster increases volume of air for

diaphragm

To increase
Almost

the speed of operation

a essential component of a vent

valve
Pressure

booster also used for increasing

the speed of control valves by increasing
the pressure.

Flashing / Cavitations
Flashing

Just like a sand blasting

Flashing liquid contains vapours
Vapours acts like a sand and liquid acts like a
carrier
Cavitation

Two stage phenomenon

1st stage Formation of voids or cavitations
with the liquid system

Flashing / Cavitations
2nd

stage Collapse or implosion of the

cavitaion back to the liquid

Result

Cavitaion Damage of trim

material of

valves.

Flashing

Cavitation

Complete Valve

To Inspect Trim Material

Marking

the side of yoke with bonnet

Marking

the side of bonnet with body

Noting
Valve

Threads

is under Bench Set Pressure

To release

the bench spring pressure, apply

signal to open the valve
Even the valve is faulty and not in operation
condition.

Yoke / Bonnet Marking

To Inspect Trim Material

Loose

coupling / Connector

The

lift of valve should be not more than

10%.

After

disconnecting stem & coupling,

Remove Check nut of yoke

Remove
Loose

Valve Actuator etc.

bonnet bolts

To Inspect Trim Material

Inspect
Seat

every trim material especially

Ring

Plug
Gaskets
Body

erosions

Bonnet

erosions

To Inspect Trim Material

Any

crack

Not

leave any thing abnormal.

Replace

Glands

If OK then insert one or more rings if possible

Outer

surface of seat and plug are usually

made harden.
If machining is required then be careful about
the depth of cut.

To Inspect Trim Material

If

cage is being used then

Check
Back
If

its sealing gasket

up rings

not original available then locally

fabricated should match the material with
process.

Sealing Gasket / Back up Ring

Tightening Procedure

To Dismantle Diaphragm
Marking
Spring

Force

Bench

Set

Usually

Force becomes minimum, while

loosing the nut / bolts

Four

long bolts

To Dismantle Diaphragm

To Dismantle Diaphragm

Installation

Control Valve With Two [Link]

Dryer

Control Valve Loop

Control Valve
Volume Booster
110 V DC
SOV
Positioner
Regulator
3 to 15 PSI Signal

NRV
Supply

Capacity Tank

SOV
De-Energized

Energized
Supply

Bleed

Out Put

Precautions
In

case of Electric device such as

SOV
Must have Explosion proof class.
When working at terminal or in J.B.
It is in open condition, one must be more
careful, because Explosion proof system is
violated.

Control Valve Loop

Lock Up Relay

Regulator

Positioner

3 to 15 PSI Signal

NRV
Supply

Capacity Tank

Setting Procedure of Lock Up Device

To provide

Regulated supply.
Monitor the supply at out put gauge
No leakage should other ports
Decrease the set pressure, Port should
change its path.
E Port pressure gauge should indicate the
above signal pressure.
Repeat the same procedure for other ports
also.

Checking & calibrating Procedure of Lock Up Device

Supply
Signal

Control Valve Loop

Valve Loop

Hand Jack / Hand Wheels

Top

Mounted

Side

Mounted

Two

Hand Jacks

Hand
Must

Jacks can be used as Stopper

have opened 5%, 10% or should not

be closed more than 90%.

Auto/Manual Procedure of Control Valves (A)

Auto

to Hand Jack

Check the hand jack indicator is in neutral

position.
Move the hand jack clockwise / anti-clockwise
to engage the lever mechanism.
Close instrument air supply of control valve.
Move the hand wheel clock wise or anti-clock
wise to open or close the valve.

Auto/Manual Procedure of Control Valves (A)

Hand

Jack to Auto

Inform

control room crew to give the signal of

controller according to the valve opening.

Open

instrument air supply of control valve.

Move

the hand wheel to neutral position slowly.

Check

pressure gauge indication of signal to the

diaphragm for further confirmation.

Side Mounted Hand Jack

Side Mounted Hand Jack

Auto/Manual Procedure of Control Valves (B)

Auto

to Hand Jack
Move the handwheel clockwise to engage
valve stem with handwheel by inserting pin
in it.
Open instrument air by pass valve of piston
Move the handwheel clockwise / anticlockwise to open / close the valve
respectively.
Always check the heath of inserting pin.

Auto/Manual Procedure of Control Valves (B)

Hand

Jack To Auto
Close instrument air signal by pass valve.
Inform Control room crew to give out put
signal of controller according to the valve
opening.
Remove the pin and disengage the stem and
hand wheel.
Move the handwheel to full anti clock wise
position.

Auto/Manual Procedure of Control Valves (B)

Auto/Manual Procedure of Control Valves (B)

Auto/Manual Procedure of Control Valves (C)

Auto/Manual Procedure of Control Valves (C)

Auto/Manual Procedure of Control Valves (B)

Louver

Different Type of Hand Wheels

Different Type of Hand Wheels

Leakage
Between:

Seat & Plug

Cage & Plug
Packing Material (Glands)
Bonnet
Flanges

To Check Valve is Passing

1.

Down stream isolating valve

2.

Body Temperature

3.

Valve Opening Reduces 50% 35%

4.

Abnormal Sound

Valve Sizing
Liquid

G
Cv Q
P

Gases

Q
TfG
Cv
1360 P( P 2)

Steam & Vapours

Cv
63.3 P

Valve Sizing

Where
Cv = Flow Rate

liquid (gpm)
- gases (scfh)
- vapours (lb/h)
G=
Specific gravity of the process.
Tf =
Flowing temperature in degree F
P =
Process drop in PSI (P1-P2)
P1 =
Upstream Pressure at valve inlet in
PSI absolute
P2 =
Downstream Pressure at valve
discharge in PSI absolute
= Down stream specific volume in cubic feet per
pound

Jacketed Valve

Globe Style
V-Port
Double

Seated

to 24

General

Service

Leakage

0.5% of Rated CV

Small Actuator

Seat

Force Required than Single

Globe Style

Single Seated
Single

Seated

Top and Bottom Guided

1

16

General

Service

Leakage

0.01% of Rated CV

Single Seated

Single Seated
Single
Top

Seated

Guided

- 16 (30 Max)

General

Service

Leakage

0.01% of Rated CV

Single Seated-Top Guided

Cage Design
1

12

Better
More

Plug Guiding

Stable Throttling

Quick

Change Trim

Cage

Angle

- 12

Y Style

-14

Used

more frequently in On Off Service

Corrosive

service

Complete Control Valve

Direct Action Double Seated

Reverse Action Double Seated

Reverse Action Single Seated

Double Seated Top & Bottom Guided

Single Seated -Top Guided

Single Seated

Linear Valve

Direct Action

Reverse Action

3 Way Valve