CONTROL VALVES

BY
SAKTHIVEL PALANI
110116074
• WHAT ARE CONTROL VALVES? INDEX
• PERFORMANCE CHARACTERSITICS OF CONTROL VALVE.
• DIFFERENT TYPES OF CONTROL VALVES
• GATE VALVE.
• GLOBE VALVE.
• PLUG VALVE.
• SOLENOID VALVE.
• BUTTERFLY VALVE.
 WHAT ARE CONTROL VALVES?
THE MOST COMMON FINAL CONTROL ELEMENT IN THE PROCESS CONTROL INDUSTRIES IS THE
CONTROL VALVE. THE CONTROL VALVE MANIPULATES A FLOWING FLUID, SUCH AS GAS, STEAM,
WATER, OR CHEMICAL COMPOUNDS TO COMPENSATE FOR THE LOAD DISTURBANCE AND KEEP
THE REGULATED PROCESS VARIABLE AS CLOSE AS POSSIBLE TO THE DESIRED SET POINT.
 TYPES OF CONTROL VALVE DESIGN
• DEPENDING ON THE ACTION OF THE CLOSURE MEMBER:
• SLIDING-STEM AND ROTARY.
• SLIDING-STEM VALVES: USE LINEAR
• MOTION TO MOVE A CLOSURE MEMBER INTO
• AND OUT OF A SEATING SURFACE.
• ROTARY VALVES: USE ROTATIONAL MOTION TO TURN A CLOSURE
• MEMBER INTO AND OUT OF A SEATING SURFACE
 PERFORMANCE CHARACTERISTICS OF
CONTROL VALVE
• DEAD BAND
• ACTUATOR/POSITIONER DESIGN
• VALVE RESPONSE TIME
• VALVE SIZING
 DEAD BAND
• DEAD BAND IS A MAJOR CONTRIBUTOR TO EXCESS PROCESS VARIABILITY. CONTROL VALVE ASSEMBLIES CAN
BE A PRIMARY SOURCE OF DEAD BAND IN AN INSTRUMENTATION LOOP DUE TO A VARIETY OF CAUSES
SUCH AS FRICTION, BACKLASH, SHAFT WIND-UP, RELAY OR SPOOL VALVE DEAD ZONE, ETC.
• DEAD BAND IS A GENERAL PHENOMENON WHERE A RANGE OR BAND OF CONTROLLER OUTPUT (CO) VALUES
FAIL TO PRODUCE A CHANGE IN THE MEASURED PROCESS VARIABLE(PV) WHEN THE INPUT SIGNAL REVERSES
DIRECTION. WHEN A LOAD DISTURBANCE OCCURS, THE PROCESS VARIABLE (PV)DEVIATES FROM THE SET POINT.
THIS DEVIATION INITIATES A CORRECTIVE ACTION THROUGH THE CONTROLLER AND BACK THROUGH THE
PROCESS. HOWEVER, AN INITIAL CHANGE IN CONTROLLER OUTPUT CAN PRODUCE NO CORRESPONDING
CORRECTIVE CHANGE IN THE PROCESS VARIABLE. ONLY WHEN THE CONTROLLER OUTPUT HAS CHANGED
ENOUGH TO PROGRESS THROUGH THE DEAD BAND DOES A CORRESPONDING CHANGE IN THE PROCESS
VARIABLE OCCUR
 VALVE RESPONSE
FOR OPTIMUM CONTROL OF MANY PROCESSES, IT IS IMPORTANT THAT THE VALVE REACH A SPECIFIC
POSITION QUICKLY. A QUICK RESPONSE TO SMALL SIGNAL CHANGES (1% OR LESS) IS ONE OF THE
MOST IMPORTANT FACTORS IN PROVIDING OPTIMUM PROCESS CONTROL. IN AUTOMATIC,
REGULATORY CONTROL, THE BULK OF THE SIGNAL CHANGES RECEIVED FROM THE CONTROLLER ARE
FOR SMALL CHANGES IN POSITION. IF A CONTROL VALVE ASSEMBLY CAN QUICKLY RESPOND TO
THESE SMALL CHANGES, PROCESS VARIABILITY WILL BE IMPROVED.
 VALVE REPONSE TIME
VALVE RESPONSE TIME IS MEASURED BY A PARAMETER CALLED T63. T63 IS THE TIME MEASURED
FROM INITIATION OF THE INPUT SIGNAL CHANGE TO WHEN THE OUTPUT REACHES 63% OF THE
CORRESPONDING CHANGE. IT INCLUDES BOTH THE VALVE ASSEMBLY DEAD TIME, WHICH IS A
STATIC TIME, AND THE DYNAMIC TIME OF THE VALVE ASSEMBLY. THE DYNAMIC TIME IS A
MEASURE OF HOW LONG THE ACTUATOR TAKES TO GET TO THE 63% POINT ONCE IT STARTS
MOVING.
 VALVE SIZING
OVERSIZING OF VALVES SOMETIMES OCCURS WHEN TRYING TO OPTIMIZE PROCESS
PERFORMANCE THROUGH A REDUCTION OF PROCESS VARIABILITY. THIS RESULTS FROM USING
LINE-SIZE VALVES, ESPECIALLY WITH HIGH-CAPACITY ROTARY VALVES, AS WELL AS THE
CONSERVATIVE ADDITION OF MULTIPLE SAFETY FACTORS AT DIFFERENT STAGES IN THE PROCESS
DESIGN. OVERSIZING THE VALVE HURTS PROCESS VARIABILITY IN TWO WAYS. FIRST, THE
OVERSIZED VALVE PUTS TOO MUCH GAIN IN THE VALVE, LEAVING LESS FLEXIBILITY IN
ADJUSTING THE CONTROLLER. BEST PERFORMANCE RESULTS WHEN MOST LOOP GAIN COMES
FROM THE CONTROLLER.
 • GATE VALVE
• GLOBE VALVE
DIFFERENT • PLUG VALVE
CONTROL VALVES • SOLENOID VALVE
AVAILABLE
 GATE VALVES
Gate valves are the most common valves in use.
They have good shut off characteristics when closed
and low pressure drop when fully open. The name
‘gate’ is derived from the design of full flow straight
through passage, when the valve is in the fully open
position. The valve gate closes the opening, usually
in a vertical sliding action that wedges itself against
the seating surfaces in the valve body. In Figure , two
gate valves are shown; one in the fully open position,
the other in the fully closed.
 GLOBE VALVES
Globe valves are designed to regulate or to stop the
flow of fluids. Normally they are in a partially open
position or fully closed. They are rarely fully open.
The valve body internal design is such that the flow of
fluid through the valve, passes under the disc and
over the seat. With this change of direction inside the
valve, turbulence occurs. The turbulence causes an
increased pressure drop across the valve. For
comparison, Figure shows the flow path through both
globe and gate valve bodies, both of which are in the
fully open position.
GLOBE VALVE
 PLUG VALVES
• THE PLUG DISC IS CONE SHAPED AND THE SEAT RING HAS A MATCHING CONE SHAPED
CENTRE. IT IS GENERALLY USED FOR HEAVY THROTTLING SERVICE, BUT HAS A DISADVANTAGE
IN THAT ABRASIVE PARTICLES CONTAINED IN THE PROCESS FLUID CAN CHIP OR NICK THE DISC
AND SEAT. THE COMPOSITION DISC IS MADE FROM TWO DIFFERENT MATERIALS.
• WHEN COMPLETELY CLOSED THE SEAT RING MAKES CONTACT WITH THE SOFT PART OF THE
DISC. ANY FINE PARTICLES CONTAINED IN THE PROCESS FLUID CAN EMBED THEMSELVES IN
THE SOFT PART OF THE DISC. THIS ACTION DOES NOT DAMAGE THE SEAT AND DOES NOT
AFFECT THE POSITIVE SHUT-OFF CHARACTERISTIC OF THE VALVE.
PLUG VALVE
 PLUG VALVES
This type of valve was probably derived from the simple wooden type cock valve used for
hundreds of years for wine and beer barrels.

The part of the valve that controls the opening is called the plug. The plug is usually tapered,
made from a single piece of metal and has a hole or slot through its centre to allow fluids to
flow through it when it is in the open position.

One quarter turn of the valve handle, fully opens or fully closes the valve.

The line of flow through a plug valve is straight. The opening of the plug is closely matched
with the opening of the body of the valve. With the valve in the fully open position the plug
offers little resistance to flow. Figure 13 shows the plug valve in both the fully open and the
fully closed positions.
SOLENOID VALVES
 BUTTER FLY VALVE
THE BUTTERFLY VALVE BODY CONTAINS A CIRCULAR METAL DISC WHICH TURNS ON A CENTRAL
AXIS. ACTUATION CAN BE EITHER MANUAL OR AUTOMATIC DEPENDING ON SERVICE
REQUIREMENTS.
THE BUTTERFLY VALVE IS GENERALLY USED FOR CONTROLLING HIGH FLUID FLOWS AT LOW
PRESSURES. WHEN FULLY OPEN THE VALVE OFFERS STRAIGHT THROUGH FLOW WITH LOW
RESISTANCE AND LOW PRESSURE DROP.
BUTTER FLY VALVE