CONTROL VALVES

TYPES, BASIC TERMS,

MAINTENANCE

Control Valves
Control Valve: A power operated device, which
modifies the fluid flow rate in a process control
system. It consists of a valve connected to an
actuator mechanism that is capable of changing
the position of a flow controlling element in the
valve in response to a signal from the controlling
system.

Valve
Valve: A valve is a device used for the control
of fluid flow. It consists of a fluid retaining
assembly, one or more ports between end
openings and a movable closure member,
which opens, restricts or closes the port(s).

Actuator
Actuator: An actuator is a fluid powered or
electrically powered device, which supplies
force and motion to a valve closure
member.

CONTROL VALVES

Basic Types

Types of Globe Valve

Simple Globe Valve

Angle Valve

Three Way Globe Valve

Types of Globe Valve

Double Ported Globe Valve

Rotary Valves

Butter Fly Valve

Plug Valve

GLOBE CONTROL VALVE

Introduction
Globe valve: A valve with a linear motion closure member, one or more ports
and a body distinguished by a globular shaped cavity around the port region.

Body
Body: The part of the valve which is the
main pressure boundary. The body also
provides the pipe connecting ends, the fluid
flow passageway, and may support the
seating surfaces and the valve closure
member.

Parts of Bonnet
1. Bonnet: That portion of the valve pressure
retaining boundary which may guide the
stem and contains the packing box and stem
seal. It may also provide the principal
opening to the body cavity for assembly of
internal parts or be an integral part of the
valve body. It may also provide for the
attachment of the actuator to the valve body.
2. Bonnet gasket: A deformable sealing
element between the mating surfaces of the
body and bonnet. It may be deformed by
compressive stress or energized by fluid
pressure within the valve body.
3. Bonnet bolting: A means of fastening the
bonnet to the body. It may consist of studs
with nuts for a flanged bonnet joint, studs
threaded into the bonnet neck of the body,
or bolts through the bonnet flange.

Bonnet Types

Bonnet types: Typical bonnets are

bolted, threaded, or welded to or
integral with the body. Other types
sometimes used are defined below.'
Extension bonnet: A bonnet with a
packing box that is extended above
the bonnet joint of the valve body
so as to maintain the temperature of
the packing above or below the
temperature of the 'process fluid.
The length of the extension bonnet
is dependent upon the difference
between the fluid temperature and
the packing design temperature
limit as well as upon the valve body
design.

Bonnet Types
Bellows Seal Bonnets
Bellows seal bonnets (figure 3-18) are
used when no leakage (less than
1x10-6 cc/sec of helium) along the
stem can be tolerated. They are often
used when the process fluid is toxic,
volatile, radioactive, or highly expensive.
This special bonnet construction
protects both the stem and the valve
packing from contact with the process
fluid. Standard or environmental packing
box constructions above the bellows
seal unit will prevent catastrophic
failure in case of rupture or failure of
the bellows.

Stem Seal
Stem seals: The part or parts needed to effect a
pressure-tight seal around the stem while
allowing movement of the stem.
Packing Box: The chamber, in the bonnet,
surrounding the stem and containing packing and
other stem sealing parts.
Packing follower: A part which transfers
mechanical load to the packing from the
packing flange or nut. Lantern ring: A rigid
spacer assembled In the packing box with
packing normally above and below it and
designed to allow lubrication of the packing
or access to a leak-off connection.
Pressure energized stem seal: A part and/or
packing material deformable by fluid
pressure that bears against the stem to make a
tight seal.
Bellows stem seal: A thin wall, convoluted,
flexible member which makes a seal between
the stem and bonnet or body and allows stem
motion while maintaining a positive seal.

Trims
TRIM: The internal parts of a valve which are in flowing contact with the controlled fluid.
Examples are the plug, seat ring, cage, stem and the parts used to attach the stem to the plug.
The body, bonnet, bottom flange, guide means and gaskets are not considered as part of the
trim.

Closure member: A movable part of the

valve which is positioned in the flow path
to modify the rate of flow through the
valve.
Plug: A cylindrical part which moves In the
flow stream with linear motion to modify
the flow rate and which may or may not
have a contoured portion to provide flow
characterization.
Seat ring: A part that is assembled in the
valve body and may provide part of the
flow control orifice.
Seat Ring also can be an integral part of
the body or cage material or may be
constructed from material added to the
body or cage.

Trims
Cage: A part in a globe valve surrounding the closure member to provide alignment and
facilitate assembly of other parts of the valve trim. The cage may also provide flow
characterization and/or a seating surface for globe valves and flow characterization for some
plug valves.

Plug Guiding
Type A:
Plug guides: The means by which the
plug is aligned with the seat and held
stable throughout its travel. The guide
Is held rigidly in the body or bonnet.
Type 1:
Stem guide: A guide bushing closely
fitted to the valve stem and aligned
with the seat. Disadvantage: Higher
pressure drops and minor cavitation
can excite vibrational modes that are
very destructive and can result in
valve failure.

Plug Guiding
Type 2:
Post guide: Guide bushing or
bushings fitted to posts or
extensions larger than the valve
stem and aligned with the seat.
Advantage: Provides rigid guiding
and ensures stable operation
even in high pressure service.
Also eliminates the need for a
larger stem by allowing large
guide surface.

Plug Guiding

Type B:
Cage guide: A valve plug fitted to the inside diameter of the cage to align the
plug with the seat.
Type 1:
Balanced trim: An arrangement of
ports and plug or combination of
plug, cage, seals and ports that tends
to equalize the pressure above and
below the valve plug to minimize
the net static and dynamic fluid flow
forces acting along the axis of the
stem of a globe valve.
Plug is guided throughout its
travel and eliminates vibrations
due to lateral thrust on the plug
and hence suited for higher
pressure drop application.
Balancing reduces stem force and
actuator size.
Quick-Change Trim & Easy

Plug Guiding
Type 2:
Un-Balanced trim: Combines
advantages of superior cage
guiding and single seated leak
tightness.

Plug Guiding
Type 1 :
Top & Bottom guide: Eliminates the
possibility of cantilever geometry of the
top guided plug with its top & bottom
guiding. Also it incorporates simplest
form of balanced construction, thereby
eliminating need for oversized actuators
in large size application. These valves
are also relatively insensitive to dirt with
its large flow passages.

Plug Guiding
Type 2:
Port guide: A valve plug
with wings or a skirt
fitted to the seat ring
bore. This also is an
economical
and
effective method for
restraint of the plug.

ACTUATORS

Diaphragm Actuators
Actuator consists of complete assembly of parts required
to operate a specific valve. Pneumatic actuators converts
the energy of a compressible fluid, usually air into motion.
In Diaphragm actuators, the fluid acts upon the flexible
member (diaphragm) to provide linear motion to the
actuator stem.

Actuators

Air Fail to Open ( FO )

Air Fail to Close ( FC )

BASIC TERMS

Basic Terms: Cv
CONTROL VALVE FLOW COEFFICIENT (Cv)
Cv is the number of U.S. gallons per minute of water which will pass through a given flow
restriction with a pressure drop of 1 psi.
Eg. : A control valve which has a Cv of 12 has an effective port area in the full open position
such that it passes 12gpm of water with 1 psi pressure drop.
INCOMPRESSIBLE FLUIDS

COMPRESSIBLE FLUIDS

Subcritical Cv= 1.16Q*Gf

Subcritical Cv=Q*(GTZ

P
Q increases,
Cv increases

295*P(P1+P2)
Q increases,

Cv increases

Pincreases,

Cvreduces

P,P1,P2increases,
Cvreduces

Basic Terms: Cf
CRITICAL FLOW FACTOR(Cf)
As illustrated when a fluid passes through the
valve orifice, there is a marked increase in
velocity. This velocity increase is accompanied
by a proportional decrease in pressure. Velocity
reaches a maximum and pressure a minimum at
the smallest cross sectional flow area
downstream of the orifice (the vena contracta).
Downstream of the vena contracta the fluid
decelerates and consequently the pressure
increases or recovers, i.e., the term pressure
recovery. It is to be noted that streamlined
valves such as Ball valves or Butterfly valves
exhibit a high degree of pressure recovery.
Globe valve style, on the other hand, exhibits a
much small amount of pressure recovery. The
critical flow factor (Cf) is effectively an index of
pressure recovery in a control valve. High Cf
values indicate low pressure recovery where a
low Cf value is an indication of high pressure
recovery.

Sub critical flow.

P1
P2
Cf =

P1 - PVC

Pvc

P1

P 1- P 2

Pvp

Critical flow!!

P2

Pvp
Pvc

The Critical
flow factor (Cf)
brings a
relationship
between the
the Inlet
pressure, P1,the
Outlet pressure,
P2 and the Vena
Contracta
pressure, PVC.

CAVITATION
Cavitation is a two stage process consisting of:
Formation of vapour bubbles when the pressure of the liquid falls below
its vapour pressure.
Collapsing (imploding) of these vapour bubbles (cavities) when the
pressure recovers to above the vapour pressure.
In valves there is a chance for occurrence of cavitation when the Outlet
pressure is close to the Vena Contracta pressure.
At the Vena Contracta the pressure may fall below the vapour pressure of
the liquid leading to the formation of vapour bubbles. As the pressure
recovers towards the outlet the vapour bubbles implode with a release of
a large amount of energy which can lead to erosion of trim parts.

Basic Terms: Flashing

P1

Two phase flow!!

Pvp
P2
Pvc

Flashing is a process in which

the pressure of the liquid falls
below the vapour pressure thus
leading to the formation of
vapour bubbles. The subsequent
flow will be two phase consisting
partly of liquid and partly
vapour.
Flashing leads to high flow
velocities which can damage
both the trims and the body
(sand blasting effect).

VALVE CHARACTERISTICS

VALVE CHARACTERISTICS
Linear: Linear trim provides equal increases in flow rate for equal
increases in plug lift. Thus the flow rate is linear with plug position
throughout its travel. This type of trim should be specified if the
control valve is to absorb most of the system pressure drop.
Equal Percentage: Equal percentage trim provides equal
percentage increase in rate of flow for equal increments of plug lift.
In this case small flow passes correspond to large changes in lifts as
the plug first leaves the seat and vice-versa towards the full open
position. This type of trim should be specified if the control valve is
to absorb a small portion of the total system pressure drop.

VALVE CHARACTERISTICS

Basic Terms: Characteristic

LIFT % (L)

LINEAR

10
20
30
40
50
60
70
80
90
100

10
20
30
40
50
60
70
80
90
100

FLOW CHARACTERI STI CS (Cv)

EQUAL
MODIFIED
PERCENTAGE
PARABOLIC
2.95
1
4.37
4
6.47
9
9.56
16
14.14
25
20.91
36
30.92
49
45.72
64
67.62
81
100
100

ON /OFF
7
24
45
68
83
92
95
98
100
100

Plug Profiles

Cage Profiles

Basic Terms: Seat Leakage

Control valve users specify leakage based on an International standard
ANSI/FCI 70.2. The Leakage Class specified is as follows:
Class I - Understanding between supplier and purchaser.
Class II - 0.5% of rated valve flow coefficient
Class III - 0.1% of rated valve flow coefficient
Class IV - 0.01% of rated valve flow coefficient
Class V - 5 x 10-4 ml/min. of water/ psi of shut off pressure/ inch of orifice dia.
Class VI - Bubble tight leak (measured as number of bubbles)

SELECTION OF ACCESSORIES.
1. POSITIONER (Valve mounted)
A positioner is a device, pneumatic, electro-pneumatic or digital, which, by using a
control signal precisely positions the moving parts of a control valve in accordance
with the signal value.
Positioners may be used for the following reasons:
Permit greater accuracy & process control
Maintain position regardless of changing forces
Handle high air pressures
Increase speed of operation
Permit faster speed of response
Change characteristics
Provide simple adjustments including split ranging
A. Pneumatic - most common type:
Usually, operates on a 0.2 to 1.0 Kg/Cm2g input signal
B. Electropneumatic - Operates on a 4-20 mA input signal

4. SOLENOID VALVE (Valve mounted)

Commonly3-waytypevalveusedinon-offservice:whensolenoidisenergized,air
supply is applied directly to the actuator completely opening or closing the valve:
when de-energized, actuator pressure is vented to atmosphere allowing the
actuatorspringtofullystrokethevalvetotheoppositeposition.
Solenoidvalvesareusedinasthecontrolmechanismtoopenorclosethevalvein
on/offapplicationswhereapositionerisnotrequired.
5. VOLUME BOOSTER (Valve mounted)
Pneumatic device whose output volume is greater than its input signal thus
increasingvalvestrokingspeed.
Pneumatic relay used in conjunction with a volume tank to transfer volume tank
pressuretoaspringlessactuatortoensurepropervalvefailureduringlossofplant
air.

6. AIR SET (Valve mounted)

Supply air pressure reducing regulator (with internal filter
and relief valve) used in conjunction with any of the above
air consuming devices.Air filters are used upstream of the
positionertoremoveoil,moistureandforeignmaterialfrom
theprocessairenteringthepositioner.
7. LOCK UP VALVE (Valve mounted)
Pneumaticrelaywhichlocksintheactuatorpressureduring
loss of plant air supply causing the valve to fail-in-lastposition.
8. VOLUME TANK
Mountedonoroffthevalve;capacitytanksoraccumulators
used to store air pressure f or transfer to a springless
actuator to ensure proper valve failure during loss of plant
air.

10.LIMIT SWITCHES
Valve mounted: Mechanical device which trips electrical switches at set
positionofvalvestroke.
11. TRAVEL STOP
Mountedintheactuator;mechanicalstopswhichvalvetravel,generallyto
preventfullclosure
12. LO-DB PLATE & CARTRIDGES
Mounted downstream of valve multistage, multi port devices which
effectively reduce valve noise upto 20 dbAby increasing the valve outlet
pressure.
13. HANDWHEELS (Valve mounted)
Handwheels allow the valve to be switched from automatic to manual
control.Sometimesusedasabuilt-intravelstop.

Thank you

Physics of the Valve Cavitation

When the fluid pressure is dropping in the valve, the pressure first drops
to the vena contracta pressure and recovers to the downstream pressure.

The vena contracta is the point at which the minimum pressure exists
and the point of maximum velocity

If the vena contacta pressure is below the vapour pressure, the liquid
boils and vapour bubbles form.

As the fluid moves further downstream the recovery phase starts.

The pressure recovery converts the kinetic energy back to potential

energy.

If the downstream pressure is more than the vapour pressure, the phase
transformation back to liquid phase occurs.

The phase transformation typically characterised by vapour implosions.

The implosion releases high amount of energy, damages the valve

internals and the body.

The cavitation problem is furher aggravated when associated with high

pressure drops which leads to excessive trim velocity.

CAVITATION PREVENTION

In Cage guided and Single seated valves with anti-cavitation trim the
destructive effects of cavitation (trim erosion) is reduced by maximising
the distance of the implosion of the vapour bubbles from the trim parts.
This is brought about by essentially giving a flow aiding to close direction.

In a Multi step Anti-cavitation valve the pressure drop takes place in

steps with the pressure directly dropping to the outlet pressure with
minimum pressure recovery. Hence the chances of formation of bubbles is
eliminated thus preventing cavitation.