CONTROL VALVES

By:
Nony Maulidya (161440030)
Wahyu Ainur Agustin (161440040)
A “control valve” works to restrict the flow
fluid through pipe at the command of an
automated signal, such as the signal from
a loop controller or logic device (such as
PLC).

2
 Get to Know Them

Some control valve designs are intended for

discrete (on/off) control of fluid flow, while others
are designed to throttle fluid somewhere between
fully open and fully closed, inclusive.

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MAIN Control Valves PARTS

Actuator Body
Provides the Contains all the
mechanical power mechanical
necessary to move components necessary
the components to influence fluid flow
within the valve body

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VALVE BODY
different types of Control Valve are based on
the design of the Valve Body itself

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1
Sliding – Stem Valves
A sliding-stem valve body is one where the
moving parts slide with a linear motion
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7
 Globe Valve
Globe valve restrict the flow of fluid by altering the distance
between movable plug and a stationary seat.
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 Globe Valve

SINGLE-PORTED GLOBE VALVE

▰ Stem-Guided

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 Globe Valve

DOUBLE-PORTED GLOBE VALVE

The purpose of double ported is to

minimize the force applied to the
stem by process fluid pressure
across the plug.

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 Globe Valve

THREE WAY GLOBE VALVE

Useful in sercives where a flow

stream must be diverted (split)
between two different
directions, or where two flow
streams must converge (mix)
within the valve fo form a
single flow stream

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 Gate Valve
Gate valve work by inserting a dam (“gate”) into the path of the
flow to restrict it, in a manner similar to the action of a sliding
door.
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 Diaphragm Valve
Diaphragm valve use a flexible sheet pressed close to the edge
of a solid dam to narrow the flow path for fluid.
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Diaphragm Valve

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2
Rotary – Stem Valves
Rotary valves rely on the rotation of a shaft
to actuate the trim
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16
 Ball Valve
A spherical ball with a passageway cut through the center
rotates to allow fluid more or less access to the passageway.
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 Butterfly Valve
Is a disk that rotates perpendicular to the path of fluid flow.

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 Disk Valve
Is a variation on the butterfly design intended to improve seat
shut-off. The disk’s center is offset from the shaft centerline,
causing it to approach the seat that results in high seating
pressure
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“ A control valve functions as a variable
resistance in a pipeline. It provides a
pressure drop by changing the turbulence in
the process fluid or, in the case of laminar
flow, the changed valve resistance or ‘drag’
cause the pressure drop. This pressure
drop is often called throttling.

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VALVE ACTUATORS
The purpose is to provide the motive force
to operate a valve mechanism.

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1
Pneumatic Actuators
Use air pressure pushing against either a
flexible diaphragm or a piston to move a
valve mechanism. 22
Pneumatic Actuators

Air pressure required to

motivate a pneumatic actuator
may come directly from the
output of a pneumatic process
control, or from signal
transducer translating an
electrical signal into an air
pressure signal (I/P)

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2
Hydraulic Actuators
Use liquid pressure rather than gas
pressure to move the valve mechanism.
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Hydraulic Valves

Application
▰ Using a piston-type ▰ The lubricating
valve rather than nature of hydraulic
diaphragm. oil helps to
overcome the
▰ It’s because the high characteristic
pressure rating of friction of piston-
pistonlends itself well to type valves.
typical hydraulic system
pressure
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3
Self-Operated
The process fluid may be directly tubed to the
actuating element, or passed through a small
mechanism called a pilot to modulate the
pressure before reaching the valve actuator.
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Self-Operated Valves

Application
▰ Gas pressure ▰ Pressure Relief
regulation. Valve (PRV)
▰ Pressure Safety
▰ Liquid Valve (PSV)
(wastewater) such
as irrigation
system.

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Pressure Regulating Valve
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4
Electric Actuators
Require a source of electrical power (often 480v
AC, three-phase).
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Electric Valves

▰ An electric actuator ▰ Most electric valve

is powered by a actuators use a worm
motor that gear set to reduce the
converts electrical high rotational speed
energy into of the electric motor to
mechanical torque. slow rotation suitable
for moving a large
valve mechanism

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5
Hand (manual) Actuators
Requiring the intervention of a human
operator to actuate
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Hand (manual) Valves

▰ A mechanical ▰ The operation of

actuator functions mechanical actuators
to execute is based on
movement by combinations of
converting one kind structural components,
of motion, such as such as gears and
rotary motion, into rails, or pulleys and
another kind, such chains.
as linear motion.

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Control Valve Actuator Principles
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CONTROL VALVE
LEAKAGE CLASS DESIGNATION
There are 6 class of Control Valve based on
its seat leakage classification
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36
VALVE FAILURE
MODE
An important design parameter of a control valve is
the position it will “fail” to if it loses motive power.

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1
Direct / Reverse Actions
The fail-safe mode of a pneumatic/spring
valve is a function of both the actuator’s
action and the valve body’s action. 38
Direct / Reverse Actions

▰ The most common

combinations mix
is a direct-acting
valve body with
either a reverse- or
direct- acting valve
actuator.

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Direct / Reverse Actions

▰ The reverse-acting
gate valve body are
shown in this
picture with fluid
flowing around the
stem while the
wide plug sits well
below the seat area

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2
Available Failure Modes
Other failure modes are possible to design
besides Fail Close (FC) and Fail Open (FO)
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42
3
Selecting The Proper
Failure Mode
It is important to note how the failure mode
of a valve is often linked to its control
action (ATO/ATC). 43
44
ACTUATORS SELECTION
We need to know the valve specification and
calculate the total force of the body valve

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Basic Valve Body Force

To operate control valve, we need these 4 main force:

A. Force to handled the Static Unbalance
B. Force on the Seat Load
C. Force to handled the Packing Friction
D. Additional Force for the Specific Aplication

𝑇𝑜𝑡𝑎𝑙 𝐹𝑜𝑟𝑐𝑒 = 𝐴 + 𝐵 + 𝐶 + 𝐷

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Data Sheet of Fisher Control Valve

▰ Action : Fail – Open (FO)

▰ Differential pressure across valve (∆P) = 80 psi.
▰ Leak Classification : Class IV (metal to metal)
▰ Body : PDTL Type : 657 P2 = 0 psi
7
▰ Port diameter = 3
16
1
▰ Travel = 1 "
2
13
▰ Boss size = 2
16
”
▰ Stem diameter = 1/2"
▰ Single TFE.
▰ Seat Leakage Classification: Class IV 47
Solution

▰ Force A
We need to know which type the control valve body is
Based on catalog 14 page 4B – 2, control valve 3" ES type 657 is classified
as Pressure Tends to Open and PDTC, thus:
𝐹𝑜𝑟𝑐𝑒 𝐴 = (Δ𝑃 × 𝐴 𝑝𝑜𝑟𝑡) + (𝑃 𝑡𝑖𝑔ℎ𝑡 𝑠ℎ𝑢𝑡𝑜𝑓𝑓 × 𝐴 𝑠𝑡𝑒𝑚)
A port = 9.28 (table)
A stem = 0.20 (table)
𝐹𝑜𝑟𝑐𝑒 𝐴 = 80 × 9.28 + 0 × 0.20
= 742.4 𝐿𝑏𝑠
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Solution

▰ Force B
We need to look for the Leak Classification on catalog 14 page B-7
𝐹𝑜𝑟𝑐𝑒 𝐵 = 𝑆𝑒𝑎𝑡 𝑙𝑜𝑎𝑑 + 𝑃𝑜𝑟𝑡 𝐶𝑖𝑟𝑐𝑢𝑚𝑓𝑒𝑟𝑒𝑛𝑐𝑒
7
Control valve class IV with port diameter 3 16
> 40 pounds per Linear INCH of port circumference (port diameter up to 4 3/8 “)
Port Circumference = 10.8 (table)

𝐹𝑜𝑟𝑐𝑒 𝐴 = 40 × 10.8
= 432 𝐿𝑏𝑠
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Solution

▰ Force C
Force C can be seen on table 6 catalog 14 page B-11 / B-12
For stem diameter 1/2" and Single TFE,
Thus, Force C = 50 Lbs.
▰ Force D
Force D = 0 ( design ES )

𝑇𝑜𝑡𝑎𝑙 𝐹𝑜𝑟𝑐𝑒 = 𝐴 + 𝐵 + 𝐶 + 𝐷 = 742.4 + 432 + 50 + 0 𝐿𝑏𝑠

= 1224.4 𝐿𝑏𝑠
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Solution

▰ Based on the Catalog 14 page B-44

With Type 657, Standard signal : 3 - 15 psi., Travel : 1 1/2"
The 1224.4 Lbs total force is near: 1404 (3-9).
▰ So we need to select the Actuator with:
Actuator size 46 ( 2 13/16 “ Yoke Boss ); force 1404
Bench set (3-9) psi.
Spring port number : 1E 826927082
Spring rate : 630 Lb/IN.

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ACTUATOR
BENCH-SET
Is the signal needed to move the stem from fully closed to
fully open or a spring adjustment needed so the actuator can
match the service condition of the process
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 Hooke’s Law
𝐹 = 𝑘𝑥
F = force applied to spring (N)
k = constant of elasticity (spring constant) (N/m)
x = displacement of spring (m)

The relationship between actuating fluid pressure and force will be:

𝐹 = 𝑃𝐴
𝑃𝐴 = 𝑘𝑥
Solving for spring displacement as a function of pressure, area, and
spring constant:

𝑃𝐴
𝑥=
𝑘
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Stem Connector and Spring Adjuster

▰ Stem connector
must be adjusted
so neither the
actuator nor the
valve trim prevents
full travel of the
valve trim.

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Stem Connector and Spring Adjuster

▰ If the stem
connector is set
with the actuator
and valve stems
spaced too far
apart (total stem
length is too long),
the result is a valve
cannot ever fully
open.
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Stem Connector and Spring Adjuster

▰ If the stem
connector is set
with the actuator
and valve stems
too closely coupled
(the total stem
length is too short),
the result is a valve
that cannot ever
fully close.
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 Bench Set Calculation (actuator type 657)

Known: Solution:
A = 69" 1
▰ Travel size = 1 8’’ ▰ Initial force = 3psi x A = (3 x 69) = 207 Lbsf

▰ Constanta spring (Ks) ▰ Spring compression force

= 550 Lbs/INCH = spring compression rate x travel
▰ Diaphragm diameter = 550 x 1 1/8 = 619 Lbsf
Spring force
(A) = 69 INCH2. ▰ Total Spring Force
▰ Standard signal = 3 = initial force + spring compression force
s/d 15 psi.
= 207 + 619 = 826 Lbsf

𝐹 =𝑃×𝐴 58
▰ Maximum force available = 15psi x 69 = 1035 Lbsf
▰ Unbalance force
= Force Available – Total Spring Force
= 1035 – 826 = 209 Lbsf
THERE IS TOTAL SPRING FORCE LESS THAN THE FORCE AVAILABLE,
SO THAT THE VALVE CANNOT FULLY OPEN
▰ Spring Setting should be 826/69 = 12PSI
▰ The Bench-Set = 3-12 psi

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 Bench Set Calculation (actuator type 657)

Known: Solution:
A = 69" 1
▰ Travel size = 1 8’’ ▰ Initial force = 3psi x A = (3 x 69) = 207 Lbsf

▰ Constanta spring (Ks) ▰ Spring compression force

= 550 Lbs/INCH = spring compression rate x travel
▰ Diaphragm diameter = 550 x 1 1/8 = 619 Lbsf
Spring force
(A) = 69 INCH2. ▰ Total Spring Force
▰ Standard signal = 3 = initial force + spring compression force
s/d 15 psi.
= 207 + 619 = 826 Lbsf

𝐹 =𝑃×𝐴 60
“ Bench-set is a very important
parameter for a control valve
because it establishes the seating
force of the plug against the seat
when the valve is fully closed.

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VALVE POSITIONER
A positioner is a motion-control device designed to actively
compare stem position against the control signal, adjusting
pressure to the actuator diaphragm or piston until the correct
stem position is reached.
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Positioner essentially act as control systems within themselves. PV, SP, MV,
handled in the positioner.

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Superior valve seating (tight shut off).

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Beneficial for the actuator which has no spring.
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CONTROL VALVE
CHARACTERIZATION
We will discusses the problem of control valve behavior in real
process application, and explores the concept of
characterization as a solution to the problem.
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Characterization of control valve is
The relationship between fluid flows through the control valve and the
valve plug travel under constant pressure condition.

▰ Quick Opening
▰ Liniear
▰ Equal Precentage

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Quick Opening Characteristic

▰ A valve using this type of plug is sometimes tends to be electrically

or pneumatically actuated an used for ‘on/off’ characteristic.
▰ The plug position responds to changes in liquid or vapour pressure
in the control system.
▰ The movement can be extremely small relative to small changes in
the controlled condition, and consequently has an inherently high
rangeability.

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Linear Characteristic

▰ The linear characteristic valve plug is shaped so that the flowrate is

directly proportional to the valve lift (H) at a constant diff. pressure.
▰ Used mostly in the Level Control or control system with slower gain
and process.

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Equal Precentage Characteristic

▰ Each increment in valve lift increases the flowrate by certain

percentage of the previous flow.
▰ Flow rate is decreased while the plug comes closer to the seat.
▰ Used mostly in faster process system.

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Depends on the valve trim

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CONTROL VALVE
PROBLEM
Control valves give a restriction when a fluid passes through
the constrictive passageways of a control valve, this specific
passageway we can called Vena Contracta
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 VENA CONTRACTA

How It Works?

Law of Continuity
𝐴1𝑣1 = 𝐴2𝑣2

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1
Flashing
Pressure recovery is below the vapour
pressure of the liquid, it occurs a flow
bubbles at the downstream valve. 75
P1

Pr
P2
Low Recovery

Vena Contracta
2
Cavitation
Pressure recovery is higher than the vapour
pressure of the liquid, it occurs a bigger
energy called Collapse. 77
 Caused

Erossion and collapse (in order to the

higher energy though the valve trim)
high velocity near the seat line of
control valve.
 THANKS!
Any questions?

Reference:
Lessons In Industrial Instrumentation by Tony R. Kuphaldt
80
BPST Peramina by Kusmintarto
https://instrumentationtools.com/