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 In most cases, processes are regulated, either

directly or indirectly, by the manipulation of
the flow rates of process and utility streams.
 Changes in flow rates are achieved by
opening and closing valves.
 Either pressure OR flow rate (not both
simultaneously) can be regulated by altering
the setting of a single valve.

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Butterfly Ball Globe Severe service

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 versatile
 often used in slurry flows
 provide speed of operation
 up to 4” diameter line
 fully open/closed by ¼ turn
 expensive
 small pressure drop (straight through hole)

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 provide almost full flow
 minimum turbulence and fluid trapping
 minimal pressure drop
 used where operation is infrequent
 100% seal
 packing wears out, high maintenance
 atmospheric leaking
 threaded stem, more cumbersome to open
 never used for throttling

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 used most often for
throttling or
modulation
 disc and seat
material must be
compatible with
fluid in service
 inexpensive, but
high pressure drop

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 fully open/closed with ¼ turn
 best suited to low pressure, low flow service
 sediment buildup usually minimal (due to
narrow body design)
 installed in up to 48” pipe
 no packing to wear out, no atmospheric
leaking
 not a positive seal except on water or steam
lines

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 prevents backflow by automatically seating
when flow direction reverses
 three basic types: swing, lift, and ball
 fluid velocities should generally be low and
nonpulsing
 installed as far as possible from pumps

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 severe service = high pressure drop = high velocity = enemy

 Cavitation potential exists

(KC>0.6)
 High vibration / noise expected
 Flashing service
 Historical knowledge
 P/P1>0.5
 Needs continuous maintenance
 Plant manager knows about the
valve

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Lost Trim &
production body wear

System Pipe
shutdown vibration

Poor Downstream
control pipe erosion

Noise High
maintenance
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Erosion &
cavitation

Vibration

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 Wellhead pressure control
 High pressure let down
 Overboard dump applications
 Fire water pump discharge
 High rangeability applications
 Gas treating
 Methanol injection
 Import / export valves
 Cavitation / flashing service

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 Rich amine letdown
 Lean amine pump recycle
 Expander bypass (JT valves)
 Emergency depressurizing
 Auxiliary power unit valves
 Import / export gas regulation
 Compressor anti-surge
 Hot gas bypass
 Process gas to vent / flare
 Slug catcher / knockout drum level
control
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 Feed gas regulator
 Slug catcher level control
 Amine pump recirculation control
 C3 / MCR / BOG compressor anti-surge
control valves
 Gas-to-flare
 Depressurizing
 Rich amine level control
 Hot gas bypass valves
 MCR / Feedgas JT (Joule-Thomson) valves

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  Compressor station  Metering station valves
◦ Compressor recycle ◦ Pipeline regulator
◦ Emergency vent ◦ Active / monitor
◦ Inlet / outlet pressure
control ◦ Slave / master valves
◦ Vent silencers

 Gas storage systems

◦ Gas injection
◦ Gas withdrawal
◦ Emergency & service vents
◦ Fuel gas regulation valves

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 Pumping station
◦ Pump recycle
◦ Export flow control
◦ PIG launcher pressure control
 Pipeline pressure reducing station
◦ Pressure letdown
◦ Surge relief
 Oil terminal
◦ Pressure letdown
◦ Metering station
◦ Tanker fill / flow control
◦ Vapor recovery systems

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 Feed gas flow regulator
 Compressor anti-surge
 Steam vent
 Lean amine pump recycle
 Rich amine letdown
 Expander bypass
 Process gas depressurizing
 Gas to vent / flare
 Auxiliary power unit valves

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 Hydrocracker unit
◦ Flash gas relief
◦ Make-up gas compressor recycle
◦ HP / HT oil letdown
◦ Feed oil surge relief
◦ Vent & pressure control
 Hydrotreater unit
◦ Recycle gas compressor anti-surge
◦ Hot & cold separator level control
◦ Feedstock pump recycle
◦ Separator vent & pressure control
 Auxiliary steam unit valves

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 Hydrogen unit
◦ Process gas to vent / flare
◦ Compressor anti-surge recycle
◦ Lean amine pump recycle
◦ Rich amine letdown
 Catalytic cracker
◦ Air compressor anti-surge
◦ Flue gas expander bypass valve
 H2S / CO2 stripper loops
◦ Rich amine letdown
◦ Lean amine pump recycle
◦ Sour water letdown

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 A CV is operated by an automated actuator to
maintain a process variable at a set point. A CV
consists of the body, bonnet, packing, trim, &
actuator assembly.
 Actuators come in many types. Typical ¼˝ valve
actuator:
◦ is pneumatically operated, spring opposed
◦ operates in response to a 12 psi range change in instrument
signal
◦ full range signal change causes the valve to stroke a distance
of about ½”
◦ standard spring has a deflection rate of 25 lbs per 1/8”
◦ spring operates against a diaphragm with an effective area of
7½”
◦ can be operated as air-to-close (ATC) or air-to-open (ATO)

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 High pressure drops
 Two-phase flows
 Erosion
 Wear
 Vibration
 Noise

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 A control valve trim refers to the inner
valve set consisting of the plug, stem
and seat. The trim is the device that is
positioned in the flow path to adjust
rates. The selection of valve trim size is
a key element in obtaining a control
valve that will provide stable operation in
the process.

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 bonnet
valve body

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 Calculate trim
coefficient

C V, liq  FL
P FL  liquid flow rate (gpm)
FG  gas flow rate (SCFH)
FG T ½ FS  steam flow rate (PPH)
C V, gas    sp. gravity relative to air or water
1360 P1  P P  pressure drop (P1 - P2, psi)
P1  upstream pressure (psia)
FS
C V, steam  P2  upstream pressure (psia)
63 P V V  sp. volume of upstream steam
T temperature

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 Compare calculates
trim coefficient to
manufacturer’s
selection chart
 Shown is the trim
size chart of Badger
Valve (Tulsa,
Oklahoma)

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 Single stage pressure
drop

P = P1 - P2

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 Multi stage pressure
drop

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Single stage pressure Multi stage pressure
drop drop

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flashpoint

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 Acceptable energy Acceptable velocity
gas / steam liquid / water
Location Psia ft / sec

Main flow piping 0.7 10

Valve inlet & outlet 24.2 60

Valve trim outlet 67.3 100

Example: Ambient temperature water

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 P Fluid velocity vs. stages Recommended
of pressure drop velocity / turns

Psi 1 stage 3 stages velocity turns

ft / sec ft / sec ft / sec
600 – 100 155 105 100 4
1500 – 100 259 172 100 10
2400 – 100 331 233 100 12
4200 – 100 441 302 100 16
Example: Ambient temperature water
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 Pressure drop
Psi 1 stage psi 3 stages psi Kinetic stages
energy psi
600 - 100 172 121 70 8
1000 – 100 288 197 70 14
2000 – 100 576 394 70 20
3000 – 100 864 605 70 28
4000 – 100 1152 620 70 32
Example: Natural gas
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 Kinetic energy criteria Velocity (H20)
Service conditions psia KPa ft/s m/s
Continuous service single 70 480 100 30
phase fluids
Cavitating & multi-phase fluid 40 275 75 23
outlet
Vibration sensitive system 11 75 40 12
Intermittent duty 150 1030 - -
 Benefits
◦ Limit vibration, erosion, noise, cavitation
◦ Provide good control

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Single stage pressure Multi stage pressure
reduction reduction

Multi path multi DRAG® disk stack

stage disk 8/2/2018 46
Three stage Four stage Eight stage
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Single stage plus diffuser Single stage
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 Up to eight stages at low
flow
 One stage at max flow

flow
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 Prescribe the minimum mandatory requirements
governing the design, sizing & selection of control
valves
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 Buyer shall specify plant operation: daily start &
stop, weekly start & stop or base loaded
 Buyer shall specify process data for normal
flow, max flow & min flow
 Buyer shall provide process conditions which
define the performance requirement of the
control valve
 Benefit: Defines plant operating requirements

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 Supplier’s basic responsibility:
1. Meet pressure boundary requirements
2. Meet max flow capacity at 80 – 95% travel
 Suppliers performance responsibility:
1. Demonstrate control of trim exit kinetic energy
to specified limits
2. Confirm methodology & meet noise requirements
3. Provide seat forces noted to meet leakage
requirements

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 1.0 Kinetic energy (velocity head)

◦ Shall be less than 70 psia (480 kPa) to eliminate

abrasion, erosion, vibration, & control noise to the
specified dBA level

◦ Kinetic energy is defined as:

 Supplier shall provide calculations

Density x V2
KE =
2gc

 demonstrating meeting the above requirements

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 2.0 Pressure reducing stages
◦ Supplier shall provide sufficient number of discrete
pressure drop stages to insure the elimination of
abrasion, erosion, & vibration
◦ Supplier shall identify the number of pressure drop
stages in proposed equipment

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 Trim outlet kinetic energy criteria
 V2 Gas / steam kinetic Equivalent liquid
KE = energy criteria / water velocity
2gc
Service conditions Psia ft / s
Continuous service single 70 100
phase fluids
Cavitating & multiphase 40 75
fluid outlet
Vibration sensitive system 11 40
Intermittent duty 150 -
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 1.0 Trim exit velocity
◦ For liquids velocity shall not exceed 100 ft/sec (30
m/sec)
◦ For flashing & cavitating, service velocity shall not
exceed 75 ft/sec (22.5 m/sec)
◦ Supplier shall provide calculation demonstrating
meeting the above velocity requirements

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 2.0 Pressure reducing stages
◦ Supplier shall provide sufficient number of discrete
pressure drop stages to insure the elimination of
abrasion, erosion, vibration, & cavitation
◦ Supplier shall identify the number of pressure drop
stages in proposed equipment

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 3.0 Application
◦ Application of velocity head criterion allows higher
fluid velocities for less dense fluids & conversly

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 4.0 Noise
◦ Noise shall be calculated in accordance with
methodology outlined in ISA SP75.17 & IEC 534-8-
3 guidelines
◦ The max noise levels shall have an upper tolerance
of +0 dBA
◦ Seller shall be required to include inaccuracies &
guarantee that the noise level, including upper
tolerance, shall not exceed specified noise level

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 Noise generated by diffusers or orifice plates
shall be calculated as a separate system from
the valve trim & included in the overall noise
level
 A max of 5 dBA credit may be used for the
application of insulation for noise reduction

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 5.0 Seat leakage
◦ Min seat leakage class (ANSI/FCI-70-2) will be IV or
V, depending on application requirement
◦ MSS-SP61 (block valve) leakage class specified for
control valves normally shut during operation
 Benefit: Prevents seat leakage degradation

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 Class IV – 300 lb/in (5.4 kg/mm)
 Class V – 500 lb/in (8.9 kg/mm)
 Class MSS SP61 (block valve)
◦ For less than 3000 psi (21 Mpa) – 1000 lb/in
(8kg/mm)
◦ For greater than 3000 psi (21MPa) 1500 lb/in (27
kg/mm)
 Force is that per linear seat ring circumference
 Seller to provide detailed calculation of seat load
 Benefit: Prevents seat leakage degradation
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to R-201 from R-201

5 6
TIC

E-202
Explain the operation of the reactor
feed heat exchanger in the DME
Process

If T5 increases, the TIC responds by

opening the control valve, reducing the
amount of Stream 6 diverted to E-202,
and thus T5 decreases. For a
4 7 decrease in temperature, the reverse
process occurs.

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to R-201 from R-201

5 6
How would this system respond to
TIC
fouling in the heat exchanger or to a
E-202
loss in catalytic activity in R-201?

Fouling – The overall heat transfer

coefficient (U) is reduced. Since the
amount of heat is Q = UAFTlm, the
only way to affect Q is to increase Tlm.
This can be accomplished by
increasing the flow of Stream 6 (closing
the valve). If fouling becomes
7
excessive, the valve will completely
4
close, and further corrective action by
the valve will be lost.

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to R-201 from R-201

5 6 How would this system respond to fouling in

TIC the heat exchanger or to a loss in catalytic
activity in R-201?
E-202
Catalyst Decay – loss in catalyst activity
results in a decrease in conversion. Exit
temperature will slowly drop (Stream 6).
This results in a drop in T5, and will initiate
the TIC to slowly close the CV. The net
effect is increased flow through E-202, and
an increase in U.

4 7 This has a further effect downstream since

the concentration of DME changes, affecting
operation of columns T-201 and T-202.

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to R-201 from R-201

5 6
TIC

What type of control strategy is being

E-202
used in this system?

Feedback Control

because the control action is initiated

by changing an input variable (amount
of flow of Stream 6 through E-202)
upon measuring a deviation in the
4 7
output variable (T5 leaving E-202).

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to R-201 from R-201

5 6
TIC

E-202
Design a control system that would
regulate the exit temperature T6 rather
than the inlet temperature T5.

Direct Method – move bypass to inlet.

4 7

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to R-201

5
from R-201

E-202 6
Design a control system that would
regulate the exit temperature T6 rather
than the inlet temperature T5.
TIC
Direct Method – move bypass to inlet.
7
This method gives us the further
advantage of being able to directly
control the conversion in the reactor
since T6 is a direct indication of
4 conversion.

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R-901
• liquid phase, exothermic reaction
• feed in stream 1 is known to vary
• heat of reaction removed by E-901
Regulate
TIC
outlet temperature
1 R-901 Regulate
FIC LIC
cw reactor inventory
E-901

Compensate for a
change in flowrate
P-901 A/B

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R-901
• liquid phase, exothermic reaction
• Hrxn partially vaporizes contents
• Vapor condensed in E-901 and returned to R-901
• R-901 operates at boiling point of contents
TIC
Regulate
E-901
reactor temperature
LIC
1 R-901
Regulate
reactor inventory
FIC LIC

Compensate for a
change in flowrate

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 Distillation column control systems -
◦ designed to produce a product stream
which has a specified composition and
neither exceeds nor falls short of this
mark (maintain quality specifications)
◦ assure column operation remains within (2) LC (1)
the operating limits
◦ prevent flooding, slugging, excessive
weeping, and dumping TC

◦ adjust conditions to protect components

(e.g., limit outlet temp of coolant to
minimize fouling in condenser tubes) (4)
 Manipulated Variables
◦ rate of (1) distillate, (2) reflux, (3) LC

bottoms, (4) reboiler duty

◦ one selected as primary manipulated
variable to achieve quality objective (3)

◦ others required maintain operating

constraints of liquid levels
 Controlled variables
◦ selected temperature, accumulator level,
reboiler level 8/2/2018 72
 Column pressure intimately tied to
column energy balance
◦ if more liquid is vaporized in
the reboiler than is condensed
in the overhead condenser,
accumulation of vapor causes PC

increase in column pressure

◦ pressure control achieved by
manipulating vapor holdup
◦ for columns with vapor products,
pressure is controlled by throttling

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 columns w/ total condensers,
rate of vapor condensation adjusted
by
◦ 1. changing condenser cooling flow
(fouling when water temps exceed 50°C)

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 columns w/ total condensers,
rate of vapor condensation
adjusted by
◦ 2. injecting noncondensable gas into
overhead (can effect temperature PC inert
of top trays; may be necessary to gas

vent;
results in containment issues
and product loss)

control by injecting inerts

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 columns w/ total condensers,
rate of vapor condensation
adjusted by
◦ 3. bypassing
inert vapor around the
condenser
PC
gas PC

control by injecting inerts control by vapor bypass

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 columns w/ total condensers,
rate of vapor condensation adjusted
by
◦ 4. using a flooded condenser

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 24 possible configurations of the 3
loops and 1 free variable
 many dismissed quickly (i.e., loop
includes entire column between
controlled variable and manipulated
variable - large time delay and large 
in transfer function  sluggish
operation)
 8 possible acceptable configurations
(2 non-conventional)
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 LC
LC

TC

TC

LC LC

composition controlled by manipulating flow rate of a product stream

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 LC LC

standard TC
configuration
TC

LC LC

initial action taken to control composition manipulates the internal recycle flow by changing the
reflux rate or the reboiler duty, which changes the boil-up rate. Subsequent actions by other loops
affect overall material balance of column.

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 LC LC

TC

TC

LC LC

one product stream is set as the “free” variable, the other is placed on level control to maintain the
column material balance. Deviations from quality specs are corrected by manipulating the
internal bulk flow rates within the column.

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THANKS