ICE471 Instrumentasi Proses

Control Valve

Budi H. Bisowarno
Jurusan Teknik Kimia
Universitas Katolik Parahyangan
April 2018
 Introduction
• When a change in a measured variable with respect to a reference
has been sensed, it is necessary to apply a control signal to an
actuator to make corrections to an input controlled variable to bring
the measured variable back to its preset value.
• In most cases any change in the variables, i.e., temperature,
pressure, mixing ingredients, and level, can be corrected by
controlling flow rates.
• One of the most common final control elements
in industrial control systems is the control valve.
• Some control valve designs are intended for
discrete (on/off) control of fluid flow, while others
are designed to throttle fluid flow somewhere
between fully open and fully closed (shut).
 Introduction
Control valves are comprised of two major parts: valve body and actuator

the valve body, which contains all the mechanical

components necessary to influence fluid flow; and

the valve actuator, which provides the mechanical power

necessary to move the components within the valve
body.

the specific components performing the work of throttling

(or completely shutting off) of fluid flow is called the valve
trim.

There are two common types of variable aperture

actuators used for flow control; they are the globe valve
and the butterfly valve.
Sliding Stem Valves
Rotary Stem Valves
 Globe Valve

• Globe valves restrict the flow of fluid by

altering the distance between a movable plug
and a stationary seat (in some cases, a pair
of plugs and matching seats).
• Fluid flows through a hole in the center of the
seat, and is more or less restricted by how
close the plug is to that hole.
• The globe valve design is one of the most
popular sliding-stem valve designs used in
throttling service.
Globe Valve
Globe Valve
Gate Valve
• Gate valves work by inserting a dam
(“gate”) into the path of the flow to
restrict it
• Gate valves are more often used for
on/off control than for throttling.
Diaphragm Valves

• Diaphragm valves use a flexible

sheet pressed close to the edge of a
solid dam to narrow the flow path for
fluid.
• These valves are well suited for flows
containing solid particulate matter
such as slurries, although precise
throttling may be difficult to achieve
due to the elasticity of the diaphragm.
Rotary Stem Valves
 Ball Valve
• In the ball valve design, a spherical ball with a passageway
cut through the center rotates to allow fluid more or less
access to the passageway.
• When the passageway is parallel to the direction of fluid
motion, the valve is wide open; when the passageway is
aligned perpendicular to the direction of fluid motion, the
valve is fully shut (closed).
 Butterfly and Disk Valves
• Butterfly valves are quite simple to understand: the “butterfly”
element is a disk that rotates perpendicular to the path of fluid flow.
• When parallel to the axis of flow, the disk presents minimal
obstruction; when perpendicular to the axis, the disk completely
blocks any flow.
• Fluid-tight shut off is difficult to obtain in the classic butterfly design
unless the seating area is lined with a soft (elastic) material.

• Disk valves (often referred to as eccentric disk valves, or as high-

performance butterfly valves) are 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 with a “cam” action that results in high seating
pressure.
• Thus, tight shut-off of flow is possible even when using metal seats
and disks.
Disk Valve
Valve Packing
• Regardless of valve type, all stem-
actuated control valves require some form
of seal allowing motion of the stem from
some external device (an actuator ) while
sealing process fluid so no leaks occur
between the moving stem and the body of
the valve.
• The general term for this sealing
mechanism is packing.
• Packing in a sliding-stem valve fits in a
section of the valve body called the
bonnet, shown in this simplified diagram
of a single-ported, stem-guided globe
valve
 Control Valve Actuator
• The purpose of a control valve actuator is to provide the motive
force to operate a valve mechanism.
• Both sliding-stem and rotary control valves enjoy the same selection
of actuators: pneumatic, hydraulic, electric motor, and hand
(manual).
Pneumatic Actuators
• Pneumatic actuators use air pressure
pushing against either a flexible
diaphragm or a piston to move a valve
mechanism.
• The following photograph shows a
cut-away control valve, with a
pneumatic diaphragm actuator
mounted above the valve body.
• Air pressure applied to the bottom
side of the diaphragm lifts the sliding
stem of the valve in the upward
direction, against the spring’s force
which tries to push the stem down
 Pneumatic Actuators

I/P Transducer
4-20 mA DC to 3-15 Psi
 Pneumatic Actuator Response
• A limitation inherent to pneumatic valve actuators is the amount of air
flow required to or from the actuator to cause rapid valve motion.
• This is an especially acute problem in all-pneumatic control systems,
where the distance separating a control valve from the controller may
be substantial.
Pneumatic Actuator Response
Pneumatic Actuator Response
Valve Fail Safe
 Valve fail safe
• An important consideration in many systems is the position of the
actuators when there is a loss of power,
• An important design parameter of a control valve is the position it will
“fail” to if it loses motive power.
• For electrically actuated valves, this is typically the last position the
valve was in before loss of electric power.
• For pneumatic and hydraulic actuated valves, the option exists of
having a large spring provide a known “fail-safe” position (either open
or closed) in the event of fluid pressure (pneumatic air pressure or
hydraulic oil pressure) loss.

• i.e., will chemicals or the fuel to the heaters continue to flow or will a
total system shut down occur?
Valve fail safe
 Valve fail safe

The automated cooling system for a large power-generating engine

Valve failure mode
Control Valves
• There are many different ways to manipulate the flows of
material and energy into and out of a process; for example, the
speed of a pump drive, screw conveyer, or blower can be
adjusted.
• However, a simple and widely used method of accomplishing
this result with fluids is to use a control valve, also called an
automatic control valve.
• The control valve components include the valve body, trim,
seat, and actuator.

Air-to-Open vs. Air-to-Close Control Valves

• Normally, the choice of A-O or A-C valve is based on safety
considerations.
Figure 9.7 A pneumatic control valve (air-to-open).
• We choose the way the valve should operate (full flow or no
flow) in case of a transmitter failure.
• Hence, A-C and A-O valves often are referred to as fail-open
and fail-closed, respectively.

Example 9.1
Pneumatic control valves are to be specified for the applications
listed below. State whether an A-O or A-C valve should be used
for the following manipulated variables and give reason(s).

a) Steam pressure in a reactor heating coil.

b) Flow rate of reactants into a polymerization reactor.
c) Flow of effluent from a wastewater treatment holding tank into
a river.
d) Flow of cooling water to a distillation condenser.
CV Characteristics
Valve Positioners
Pneumatic control valves can be equipped with a valve
positioner, a type of mechanical or digital feedback controller
that senses the actual stem position, compares it to the desired
position, and adjusts the air pressure to the valve accordingly.

Specifying and Sizing Control Valves

A design equation used for sizing control valves relates valve
lift to the actual flow rate q by means of the valve coefficient
Cv, the proportionality factor that depends predominantly on
valve size or capacity:

Pv
q  Cv f   (9-2)
gs
• Here q is the flow rate, f   is the flow characteristic, Pv is the
pressure drop across the valve, and gs is the specific gravity of
the fluid.
• This relation is valid for nonflashing fluids.
• Specification of the valve size is dependent on the so-called
valve characteristic f.
• Three control valve characteristics are mainly used.
• For a fixed pressure drop across the valve, the flow
characteristic f  0  f  1 is related to the lift  0   1 , that
is, the extent of valve opening, by one of the following relations:

Linear: f 
Quick opening: f  (9-3)
1
Equal percentage: f R
Figure 9.8 Control valve characteristics.
 CV Characteristics
• Control valves are supposed to deliver reliable, repeatable control of
process fluid flow rate over a wide range of operating conditions.
• the control valve may have behavior problem in real process
applications – control valve charcteristics
CV Characteristics
 CV Characteristics
• The globe type valve can be designed for quick opening, linear, or
equal percentage operation.
• The shape of the plug determines the flow characteristics of the
actuator and is normally described in terms of percentage of flow
versus percentage of lift or travel.
 CV Characteristics

Photographs of linear (left) and equal-percentage (right) globe valve

plugs are shown side-by-side for comparison.
CV Characteristics
CV Characteristics
CV Characteristics
CV Sizing
 CV Sizing
• The act of choosing an appropriate control valve for the expected
energy dissipation is called valve sizing.
• Valve sizing is based on pressure loss. Valves are given a Cv
number that is based on test results.
• Oversizing the valve hurts process variability.
 CV Sizing
• When a fluid moves turbulently through any restriction, energy is
inevitably dissipated in that turbulence.
• The amount of energy dissipated is proportional to the kinetic energy
of the turbulent motion, which is proportional to the square of
velocity.
CV Sizing

Cv is the valve capacity or valve characteristics

In the United States of America, Cv is defined

as the number of gallons per minute of water
that will flow through a valve with 1 PSI of
pressure drop
CV Sizing
 CV Sizing
According to the process engineers, the
maximum expected flow rate for this
valve is 470 GPM.
What should the maximum Cv rating be
for this valve?

We need a control valve with a Cv value of at least 143 to meet the

specified (maximum) flow rate. Is it safe for over-sized valve?
 Valve Sizing Example
• Size a control valve for max 150 GPM of water and min
of 50 GPM.
 Determine CV at Max and Min FV

• Use the valve flow equation (Equation 2.3.3) to

calculate Cv
• For P, use pressure drop versus flow rate (e.g.,
Table on page 82)

Fm
Cv ( x) 
K P / 
150 50
C max
v   28.9; Cv 
min
 9.1
27 /1 30 /1
Valve Position for Max and Min Flows
for Different Sized Valves

Max flow Min flow

1-inch valve not large enough 75%
1.5-inch valve not large enough 68%
2-inch valve 67% 45%
3-inch valve 55% 30%
4-inch valve 47% 22%
 Analysis of Results
• 2-inch valve appears to be best overall choice: least
expensive capital and it can provide up to a 50%
increase in throughput.
• 3-inch and 4-inch valve will work, but not recommended
because they will cost more to purchase.
• The 2-inch valve will provide more than enough extra
capacity (i.e., something else will limit capacity for it)
 CV Sizing
• Based on a given flow rate and pressure drop, a required Cv value
can be calculated. This Cv can then be compared to Cv values for a
particular valve size and valve design.
• Generally, the required Cv should fall in a range of between 70%
and 90% of the selected valve’s Cv capability.
• Allowance for minimum and maximum flow pressure conditions
should also be considered.
• Once a valve has been selected and Cv is known, the flow rate for a
given pressure drop, or the pressure drop for a given flow rate, can
be predicted by substituting and solving for the appropriate
quantities in the equation.
 Valve Selection
Beside the valve types, the choice of valve type are determined based on
corrosion resistance, operating temperature ranges, high and low pressures,
velocities, and fluids containing solids.