2015240591

Lab
experiment:
Prepared by

: Desmond Goh Kai Hong

ID number

: 2015240591

PROGRAMME

: btec higher national diploma in

Electrical/electronic engineering

SEMESTER

:3

Subject Name

: instrumentation and control

principles

Subject Code

: J/601/1417

Prepared for

: asfarina binti abu bakar

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Introduction
Regulating
used

to

Valve

is

regulate

pressure,

flow

in

rate,

automatic

regulation

system

device

temperature,

parameters.Regulating
used

a
and

other

valves

are

control

and

and

influence

the course of technological and

heat

and

power

engineering

processes in accordance with the

supplied instructions.
Regulation valve are installed
on trunk and industrial pipelines
and

engineering

installation,
regulating

and

valve

equipment,
reservoirs.

consists

of

A
a

regulating unit (the valve itself)

which

varies

the

flow

cross

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section,and

an

mechanism,which

is

actuating
a

pneumatic

drive that receives instructions

from an automatic regulator of a
remote

controlled

device

and

transmit these instruction to the

regulating unit.
Regulating valves are classified
on

the

capacity

basis

of

as

medium

their
flow,

nominal
small

flow, and micro flow valves and on

the basis of nominal pressure as
low pressure, medium pressure, and
high pressure valves. They operate
at temperatures between -225C and
450C. There are many different
types

of

regulating

valve,

including single and double seat,

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pass,

angled,

and

three

way

valves. Double seat valves with

spring
actuating

loaded

diaphragms

mechanisms

are

as
most

commonly found.
The regulating unit has a flange throughout section and consist
of top and bottom covers, a plunger, and a housing into which tow
seats have been screwed. A coupling nut connects the plunger rod
to the rod of the actuating mechanism,which is fastened to the top
cover of the regulating unit. The diaphragm sense a standard
command signal,(0.02-0.1 meganewtons/cm2 of air pressure) and
transmits its force to the return spring of mechanism,which leads to
the displacement of the rod with the gate and a change in the flow
cross section,resulting in a change in the valves throughout
capacity.

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Body

The

valve body, sometimes called the

shell, is the primary boundary
of a pressure valve. It serves
as the main element of a valve
assembly

because

it

is

the

framework

that

holds

all

the

body,

the

parts

together.The

first

pressure

boundary

of

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valve,

resists

fluid

pressure

loads from connecting piping. It

receives inlet and outlet piping
through

threaded,

welded

joints.The

bolted,

or

valve-body

ends are designed to connect the

valve to the piping or equipment
nozzle by different types of end
connections,
socket
flange.

such

welded,

as

butt

threaded

or
or

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Bonnet

The

cover

for

the

opening in
the body is
the bonnet,
and it is the
second most
important
boundary of
a

pressure

valve. Like
valve
bodies,
bonnets are in many designs and models available. A bonnet acts as a cover on the
valve body, is cast or forged of the same material as the body. It is commonly
connected to the body by a threaded, bolted, or welded joint. During manufacture of
the valve, the internal components, such as stem, disk etc., are put into the body and
then the bonnet is attached to hold all parts together inside.In all cases, the attachment
of the bonnet to the body is considered a pressure boundary. This means that the weld
joint or bolts that connect the bonnet to the body are pressure-retaining parts. Valve
bonnets, although a necessity for most valves, represent a cause for concern. Bonnets
can complicate the manufacture of valves, increase valve size, represent a significant
cost portion of valve cost, and are a source for potential leakage.

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Seat Ring
The

seat

or

seal

rings

provide the seating surface

for the disk. A valve may
have one or more seats. In
the case of a gate valve,
there are two seats; one on
the upstream side and the
other on the downstream side. A gate valve disc has two seating surfaces that come in
contact with the valve seats to form a seal for stopping the flow.To improve the wearresistance of the seal rings, the surface is often hard-faced by welding and then
machining the contact surface of the seal ring. A fine surface finish of the seating area
is necessary for good sealing when the valve is closed. Seal rings are not usually
considered pressure boundary parts because the body has sufficient wall thickness to
withstand design pressure without relying upon the thickness of the seal rings.

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Task 3

Fast opening characteristic

Figure 2: Fast
Opening Plug
Shape
These valves give a
large increment in
flow for relatively
smaller

valve

opening.

These

valves usually find

use

for

on-of

service
applications.The fast opening characteristic valve plug will give a
large change in flow rate for a small valve lift from the closed
position. For example, a valve lift of 50% may result in an orifice
pass area and flow rate up to 90% of its maximum potential. A valve
using this type of plug is sometimes referred to as having an 'on /
of' characteristic where significant flow rate must be established
quickly as the valve begins to open. Unlike linear and equal
percentage characteristics, the exact shape of the fast opening
curve is not defined in standards. Therefore, two valves, one giving
a 80% flow for 50% lift, the other 90% flow for 60% lift, may both be
regarded as having a fast opening characteristic. Fast opening
valves tend to be electrically or pneumatically actuated and used for
'on / of' control.The plug position responds to changes in liquid or
vapor pressure in the control system. The movement of this type of
valve plug can be extremely small relative to small changes in the
controlled condition, and consequently the valve has an inherently
high range-ability.

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Task 4
FAIL OPEN
Fail Open is the term where a valve opens at loss of signal. This scenario might be
chosen to prevent over pressure in the event of a blocked line or in case of a
catastrophic failure. When sizing a pneumatic actuator this is indicated as "spring to
open" or "air to close."
FAIL CLOSED
Fail Closed means the valve will closed when the signal is interrupted. An example of
this would be block valves closing to isolate a steam injection well on loss of power.
Because uncontrolled steam is dangerous and potentially lethal, automatic valve
closure might be required. When sizing a pneumatic actuator this is indicated as
"spring to close" or "air to open."

Figure 3: The fail open and fail close valve.

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In control cooling water system valve,the best design for the valve is fail open.In
cooling water system,this system was needed to cool down the heating system . For
example,the heating system that used this control cooling water system is nuclear
power plant, certain factory that use boiler and so on. It is best to use fail open design
because if there is any power failure occurs in the factory,the fail open design
automatically lose the pressure which control the spindle and open the valve for the
water to pass through. It will prevent the system from overheat and cool down the
heating system that using this type of fail open designed valve. Since the factory or
the power plant has high heating process, it is the best choice that the cooling water
valve was design with a fail open design which bring lots of benefit to the system.If
the designed valve was wrong there will be a great disadvantage for the heating
system. For example, the power plant will explode due to overheat, more expenses on
the machines that overheated and so on.

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Task 5
Globe Valve
Globe valves are so named for their globular shaped cavity around the valve seat area.
The closure member of a globe valve is a plug with a flat or convex bottom that is
lowered onto a matching horizontal seat located in the center of the valve. Raising the
plug opens the valve, allowing fluid flow.
Globe valve have good throttling characteristics but because the flow path is not
linear they have a relatively high pressure drop across the valve. Globe valves are
used in throttling and shut-off applications where this pressure drop is
acceptable.Globe valves have many advantages and disadvantages for users. They
have excellent and precise throttling ability for high-pressure systems. The
disadvantages include low-flow coefficients and a longer operating time because the
operator must turn the handle and stem many times to ensure the valve is completely
open or completely closed. Globe valves can be used in systems that require frequent
stroking, vacuum, and systems that have a wide range of temperature extremes
There are three primary body designs for globe valves which are Z body, Y body and
angle which is shown as in Figure 4.

Figue 4: Three Design of Globe Valve

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Gate Valve
The closure member of a gate valve is a flat face, vertical disc, or gate that slides
down through the valve to block the flow.
Gate valves are designed to operate in their fully open or fully closed position and
therefore are found only in flow shut-off applications. When fully open, the disc is
removed completely from the flow stream. This offers virtually no resistance to flow
when the valve is fully open, therefore gate valves operate with little pressure drop
across the valve.This leaves an opening for flow through the valve at the same inside
diameter as the pipe system in which the valve is installed. A Gate valve can be used
for a wide range of liquids and provides a tight seal when closed.Gate valves have
very poor flow throttling characteristics and are not used for throttling purposes.

Figure 5:
Gate
Valve

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Diaphragm Valve
Diaphragm valves get their name from a flexible disc which comes into contact with a
seat at the top of the valve body to form a seal. A diaphragm is a flexible, pressure
responsive element that transmits force to open, close or control a valve. Diaphragm
valves are related to pinch valves, but use an elastomeric diaphragm, instead of an
elastomeric liner in the valve body, to separate the flow stream from the closure
element.
The main advantages of a diaphragm valve is that the stem seal is eliminated.
Diaphragm valves are used mostly for shut-off services of slurries,corrosive or
viscous fluids but may also used in flow throttling application as well.
Diaphragm valves may be used in pumping applications with a set constant pressure
on the diaphragm. This allows flow to be stopped in the absence of motive force
(pump), but when a sufficient pressure is generated in the pipe to overcome the force
on the diaphragm flow is allowed.

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Figure 6: Diaphragm valve.

*elastomeric = any material,such as natural or synthetic rubber that
is able to resume its original shape when a deforming force is
removed.
If a valve was used in to control the flow of a toxic gas,the globe
valve is the best selection among others valve.Globe valves are
closing-down valves in which the closure member is moved squarely
on and of the seat. It is customary to refer to the closure member
as a disc, irrespective of its shape. By this mode of disc travel, the
seat opening varies in direct proportion to the travel of the disc. This
proportional relationship between valve opening and disc travel is
ideally suited for duties involving regulation of flow rate. In addition,
the seating load of globe valves can be positively controlled by a
screwed stem, and the disc moves with little or no friction onto the
seat, depending on the design of seat and disc. The sealing capacity
of these valves is therefore potentially high. Globe valves may, of
course, be used also for on-of duty, provided the flow resistance
from the tortuous flow passage of these valves can be accepted.
Some globe valves are also designed for low flow resistance for use
in on-of duty.Also,if the valve has to be opened and closed
frequently, globe valves are ideally suited because of the short
travel of the disc between the open and closed positions, and the
inherent robustness of the seatings to the opening and closing
movements.
Therefore, the seating in the globe valve are also the main
purpose that globe valve are choose to control the flow of a toxic
gas. There are few type of design seatings which are narrow contact
seating, ball seating and others. The narrow contact seatings have
a narrow contact face, so the seating stress is particularly high for a
given seating load. However, the narrow seat face is not capable of
guiding the disc squarely into the seat to achieve maximum sealing
performance. The ball seatings are ball shaped at the disc and

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tapered at the seat. The disc can therefore roll, to some extent,on
the seat until seat and disc are aligned. Because the contact
between the seatings approaches that of a line, the seating stress is
very high. On the debit side, the line contact is prone to damage
from erosion. The ball-shaped seatings are therefore used only for
dry gases, which are also free of solids.
Lastly, Globe valve has been designed to withstand the pressure
and structural stress and exposure to which they are subject.Hence
Globe Valve is best choice among other valve.

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Task 6
A valve positioner is a device used to increase or decrease the
air load pressure driving the actuator of a control valve until the
valves stem reaches a position balanced to the output signal from
the process variable instrument controller. Positioners are usually
separate units that attached to the valve position corresponds to the
control signal (0.2 - 1bar and 4 - 20 mA typically). The positioner is
able to provide the power needed to move or maintain the valve at
the correct position regardless of disturbance acting on the
mechanism. The positioner contain a sensor that is attached to the
valve spindle and provides a signal for comparison with the applied
control signal. Depending on the error, more or less power is applied
to the actuator to correct the position.
The positioner may be entirely pneumatic, entirely electric or a
mixture. For example the actuator may be pneumatic but the
control signal may be electric and a current to pressure converter
used.This positioning system has the advantages such as accurate
control,fast response, great actuating force (e.g to overcome friction
in the packing gland) and control over the relationship between flow
and signal which is usually linear but can be otherwise such as
square root characteristics. The figure below illustrates a valve with
the positioner fitted.

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Figure 7: Valve positioner fitted.

Reasons of using a valve positioner
By using a valve positioner,it can increase control system
resolution which increase the accuracy. For example a valve
positioner are allowed for fine control with better resolution and
accuracy through full use of signal. This ofsets the variation of
the actuators range spring rate, which can vary 8%.It also can
minimizing friction. Valve positioners can minimize friction efects
of valve stem packing and the resulting hysteresis. This is
especially beneficial for high temperature packing materials like
graphite.Besides it also can increase response time. Valve
positioners increase the response time to a change in the process. This
allows for faster loading and venting. It also can negates flow-induced
reactions to higher pressure drops.This compensates for internal force
imbalances. Apart from that it also can increased flexibility of the system.It
has the permits use of piston actuators with high instrument air supply
pressures.Besides that the selection of actuator bench-set ranges that are
not matching. Valve positioners facilitate selection of actuator bench-set
ranges that arent matching or multiple rating from the signal. For
example, using a 3-15 psig signal with a valve bench-set of 10-35 psig

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signal. However, if the larger value of the bench-set is above 15-18 psig, a
positioner is technically required.Then, it also can seating friction. Valve
positioner can Overcomes seating friction effects at travel below 10%,
allowing throttling near the closed position in a rotary control valve. Other
than that,It allow for split-ranging. Valve positioner gives the ability to use
one controller for two valves for example 4-12mA and 12-20mA. Lastly,it
has characterization cams, valve positioners allow for incorporation of
characterization cams to vary from the rotary control valves inherent
character to a formed characteristic.

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Reference
http://www.ehss.vt.edu/programs/CGC_equipment.php
http://www.resistoflex.com/replacedia.htm
http://www.ehss.vt.edu/programs/CGC_equipment.php
https://blog.craneengineering.net/11-reasons-to-install-a-valvepositioner
https://blog.craneengineering.net/11-reasons-to-install-a-valvepositioner
http://www.tlv.com/global/TI/steam-theory/types-of-valves.html
http://www.globalspec.com/learnmore/flow_control_flow_transfer/
valves/diaphragm_valves