CONTROL

VALVES
Rejath Jacob Thomas

CONTROL VALVE - An Introduction

A Control Valve is the most commonly used

final control element used to regulate fluid flow in

a process. In a process, normally it is the only
controllable element residing in the loop.
This is a device used to modulate flow of
process fluid in pipe lines by creating a variable
area in the flow path.
The flow path is varied with respect to the
control signal received from the controller
towards the required flow modulation.
2

CONTROL VALVE - ISA Definition

International Society of Automation ISA (previously known as Instrument
Society of America) defines the control
valve as a power operated device that
modulates the fluid flow rate in a
process control system

CONTROL VALVE - In a process control loop

Representation of a typical process control loop

CONTROL VALVE - PARTS

PARTS OF CONTROL VALVE

Valve body assembly

Body
Bonnet
Bolting
Seat ring
Plug
Stem
Cage
Packing
Seal ring
Gasket and shim

Pressure Retaining Components

Trim Materials

Actuator assembly
6

VALVE BODY
Main fluid boundary and pressure containing component
It Includes
Provision for securing internal parts
End connections that allows installation in the pipeline
Provision for attaching the bonnet
BODY

BONNET
Also a major pressure containing component and

fluid boundary
Bolted or threaded into valve body
Bonnet locates and guides the valve stem and it
includes a bore for packing (packing box)
Also includes yoke boss or some other means
mounting an actuator

BONNET

TRIM
Trim refers to all internal parts of a valve which
are in flowing contact with the controlled fluid
[also referred to as Wetted parts]
It includes the valve plug, stem, cage, seat ring,
plug sealing rings, gaskets and packing parts

Trim Parts

TRIM COMPONENTS
Plug

Provides throttling control and shutoff in globe valves

Seat

ring
Seat rings in globe valves work with the valve plug to
arrest leakage.

Cage
Provides plug guidance and flow characterization
Stem
Connects the plug to the actuator
10

PARTS OF CONTROL VALVE - Contd

Stem

Connector
A Clamp in two pieces to connect the actuator stem to
the valve plug stem.
STEM
CONNECTOR

YOKE

Yoke
The connecting structure / part between the Valve
Actuator and the bonnet assembly.

11

PARTS OF CONTROL VALVE - Contd

Gaskets

Provides sealing between mating surfaces.

Bonnet gasket :
Between Body and bonnet
Seat ring gasket :
Between seat ring and body
Packing

Prevents leakage of the fluid through the valve stem

Packing is compressed to form a tight seal
between the packing box wall and the valve
plug stem

12

ACTUATOR
It the part of the valve which generates the motive
power. It is the mechanism which operates the valve
plug, in correspondence to the control signal received
from the controller.
Actuators Types:
Pneumatic
Spring Diaphragm
Piston Cylinder
Electrical
Hydraulic
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VALVE ACCESSORIES
POSITIONER
Pneumatic
Electro-pneumatic
Conventional
SMART HART
Foundation Field bus
POSITION SWITCHES
Inductive
Mechanical Cam Operated

14

VALVE ACCESSORIES Cont . . .

SOLENOID VALVE
Latching type
Manual Reset
VOLUME BOOSTERS
AIR LOCK RELAY
AIR FILTER REFULATOR
AIR VOLUME TANK
HANDWHEEL
15

VALVE TERMINOLOGIES
Capacity : It is the ability of the valve to allow fluid flow through
it under stated condition.
Cv Valve Coefficient : It is the unit of measurement to define
the capacity of a valve. The number of US Gallons of water at 60
degrees F that will pass through a valve with a drop of one pound
per square inch in one minute.
VALVE Kv : Quantity of water in M3/Hr. at temperature
between 5 to 40 degrees C that will flow through the valve at a
specified travel with a pressure drop of 1 Bar.
Kv = 0.856Cv
Rated CV : Value of Cv at full open position.
16

TERMINOLOGIES Cont . .
Rangeability:
Rangeability of a Control Valve is defined as the ratio of the
maximum controllable flow to the minimum controllable flow. The
Inherent rangeability of a valve is the ratio of the maximum and
minimum flow under constant pressure differential . Hence it is
expressed as Cv Max divided by Cv min.
Leakage:
Quantity of fluid passing through an assembled valve when the
valve is in the closed position under stated closure forces with
pressure differential and pressure specified. [ref to ANSI B-16
104-1976]
17

TERMINOLOGIES Cont . .
Valve Characteristics:
It is a relation between flow through the valve & percentage
rated travel as the latter is varied from 0-100%.
Inherent characteristics:
Flow characteristics when constant pressure drop is maintained
across the valve.
Installed Characteristics:
Flow characteristics when pressure drop across the valve varies
as dictated by flow and related conditions in the system in which
the valve is installed.
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CONTROL VALVE - CLASSIFICATION

Depending on the motion of the plug

Linear

Rotary

Each type of valve has its special generic features, which

may, in a given situation, be either an advantage or a
disadvantage

19

LINEAR VALVES

ROTARY VALVES

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CONTROL VALVE - CLASSIFICATION

Depending on the motion of the plug
Linear Motion

Globe

Globe

Single Seated
Double Seated

Diaphragm

Angle

Pinch or Clamp

3-Way

Split body

Control Valve

Rotary Motion

Butterfly

Swing Through

Eccentric Plug

Lined
Eccentric

Ball

Segmented
Full
V-Notch

21

SINGLE SEATED GLOBE VALVE

Sizes : 1/2" to 16" Higher sizes available on
request
Application :
To control large range of process parameters,
specially for oil and gas production, power
generation,
chemical,
petrochemical,
fertilizer, pharmaceutical, processed food
and other process industries.

22

SINGLE SEATED GLOBE VALVE

Features :
High flow capacity and high gain
High powered actuator, field reversible
Streamlined flow passage and excellent flow control
rangeability
Tight shut off permissible
High rangeability using low flow trims
Large variety of trim design varying from contoured trims to
single stage ported and multiple stage low noise anti
cavitation trims
Can be supplied with wide range of interchangeable trim
sizes
Characteristics - Equal percentage, Linear and Quick open
Leak proof packing are available on request

23

DOUBLE SEATED GLOBE VALVE

Sizes : 11/2" to 18" (40 - 450 mm) Higher sizes

available on request

Application :
For high flow and high pressure services

24

DOUBLE SEATED GLOBE VALVE

Features :

High Flow Capacity Minimum differential plug areas to

reduce actuator force requirement
Optional anti - cavitation / low noise trim option for high
pressure drop application
Characteristics - Equal percentage, Linear, Quick open
Leak proof packing are available on request
Heavy duty top and bottom guided construction

25

ANGLE VALVE

Sizes : 1/2"

to 6"

Application :
Specially for very high pressure drop and also used where the
fluids contain solid particles.

26

DOUBLE SEATED GLOBE VALVE

Features :
u High Flow Capacity
u Tight shut off
u High rangeability
u Body proportioned to withstand high pipe stresses without

distortion
u Wide range of interchangeable trim styles and sizes

available
u Adaptability to specialist duties i.e. venturi outlet, low noise

etc.

27

THREE WAY VALVE

Definition : is ideal for blending two separate flows, by having
two inlets and a common outlet, or dividing a flow into two
proportional parts by having one common inlet and two outlets.

Sizes : 1/2"

to 12 Higher sizes available on request

Application :
For high temperature fluid and particularly for textile industries, to mix or divert fluids

28

THREE WAY VALVE

Features :
u High Flow Capacity
uLeakage capability better than ANSI class IV & consistent

with normal single seat valve

u High rangeability
u Leak proof packing are available on request
u Valve is used for mixing or diverting services depending on

customers requirement

29

THREE WAY VALVE

MIXING SERVICE

DIVERTING SERVICE

30

BELLOWS SEALED VALVE

Definition : Available as additional feature to give

a leak
proof packing in the single seated, double seated and three
way valves.
Application :

For hazardous and corrosive fluids.

Features :
u Bellows are of stainless steel to withstand high

pressure & temperature.

uPTFE bellows available for low pressures on

request.

31

BUTTERFLY VALVE

Sizes : 2"

to 36"

Application :
Steel, Sugar and textile industries and specially for fluid
containing slurry particle. Used for on-off as well as
control applications.

32

BUTTERFLY VALVE
Features :
u Water style connection Concentric design as

standard, offset design for special application

u

Metal to metal or Sleeved type construction

u Choice of various rubber or PTFE sleeves

u Tight shut off with rubber sleeves
u Minimum obstruction for flowing media
u High Flow Capacity
u Simple & Light construction

33

BALL VALVE
Sizes : 1/2" to 8" (15 - 200 mm)
Application :
Used in paper, Pulp and textile industries

Features :
Tight shut off Minimum obstruction for the flowing
media
u

u High Flow Capacity

u 'O' Ball & 'V' Notch construction available

34

DIAPHRAGM VALVE
Sizes : 1/2" to 14"
Application :
For water treatment plant, caustic soda plant, chemical
plants, fertilizers, specially for corrosive fluid.

35

Features :
u

DIAPHRAGM VALVE

Castings standardized to IS 210 FG grade cast Iron

u Better sealing and longer diaphragm life with the help of weir

design
u Stronger bonnet design to take care of higher thrust and

support to the diaphragm

u Diaphragm construction design with exclusively reinforced

fabric
u Fail safe assembly on auto valves totally protects process

operation in the event of electrical power or air supply failure

u Available in various linings to handle different fluids

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VALVE CLASSIFICATION - ACTUATOR TYPE

37

VALVE CLASSIFICATION END CONNECTION

SCREWED
WELDED END
BUTT WELDED
SOCKET WELDED
FLANGED END
RAISED FACE, RF
FLAT FACE, FF
RING TYPE JOINT, RTJ
WAFER TYPE
WELDED END
WELDED END
38

End connection Screwed end

Popular for small control valves because of their economy and
ease of installation
Not available for bodies above 2 inch in size
Aligning the threaded in valve with pipelines needs extreme care
and mismatch may lead to damage to thread in valve

39

End connection Welded end

For high pressure and high temperature applications

Valve body is directly welded into the pipeline
Leak tight at all pressure and temperature
Economical
Socket weld ends are common for smaller valve sizes and butt
weld ends are standard for sizes 2-1/2 inch and larger valve bodies
Precise alignment of valve body with pipe line is mandatory for
welded end connection

Butt Weld

Socket Weld
40

Butt welded end

Butt Weld end

Connection

41

End connection Raised Face (RF)

Most common end connection
Flange has circular, raised faces with concentric circular grooves
for good gasket sealing and resistance to gasket blowout
Gasket only covers the raised face portion of the flange
As line bolting is tightened, high stresses are produced at the
perimeter of each flange
Not available for brittle/Soft material like Cast Iron, Bronze etc.

42

End connection Flat Face (FF)

Allows full face contact with gasket clamped between the flanges
Full face contact has the advantage of minimizing flange stresses
caused by forces of line bolting
This type of flanges are common in cast iron bodies which are
brittle and would crack if raised face flanges were used. Flat face
flanges are also common in brass and aluminum bodies
These materials are soft and would bend if raised face flanges
were used

43

End connection Ring type joint (RTJ)

Well suited for extremely high pressure applications but generally
not used at high temperature
Mating grooves in the body and pipe flanges retain a solid metal
seal ring
As the line bolting is tightened the ring deforms and conforms to
the grooves
Pressure assisted seal; since as the pressure increases, the ring
pushes against the grooves
Soft iron or Monel is generally used as gasket material

44

End connection Separable flange

Flanges are manufactured independently of the valve body
Split rings are required to secure the flange to the body and to
transmit the bolting force to the gasket and mating connection
If the body material is expensive separable flanges may result in
economy since flanges can be made of an economical material
like carbon steel

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End connection Wafer style

Generally called as Wafer style or flangeless
Includes a raised-face contact surface in the body casting
Long line bolting sandwiches the body and gasket between the
pipe flanges
This is more economical body style since it requires less material
for construction
Ball and butterfly valves are commonly available with this body
style

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Shutoff class
Importance of control valve shutoff
To maintain proper operation of a process
If a control valve leaks excessively in closed position the
leakage may affect the downstream processes & end
product quality
To avoid potential damage to the valve in certain applications
If a valve in boiler feed water application leaks, the high
velocity streams that leaks across the seat can erode
critical seating surfaces

47

Shutoff class
The ability of a control valve to prevent flow from the inlet side
to the outlet side of the valve in the fully closed condition.
ANSI/FCI 70-2 came up with different shutoff classes to
standardize leakage across control valve
To provide a range of shutoff options linear valves have
different type of plug and seat construction
Rotary valves have various seal configuration and materials to
offer a range of shutoff

48

Shutoff class
ANSI/FCI Leakage Classes
ANSI/FCI 70-2
Class II
Class III
Class IV
Class V

Maximum Leakage
0.5% valve capacity at full travel
0.1% valve capacity at full travel
0.01% valve capacity at full travel
0.0005ml/min/psid/in. port dia
Port dia.

Class VI

1
1 - 1/2
2
2 - 1/2
3
4
6
8

Test Medium Pressure and temperature

Service DP or 50 PSID
Water / Air whichever is lower at 10 to
52deg C
Water
Service DP at 10 to 52deg C

Bubbles per
mL per Min.
Min.
1
2
3
4
6
11
27
45

0.15
0.30
0.45
0.60
0.90
1.70
4.00
6.75

Air

Service DP or 50 PSID
whichever is lower at 10 to
52deg C

49

Flow Characteristic

Relationship between flow through the valve and the

plug/disc travel.

Flow Characteristics
Quick opening-Shut off & Fast flow
Linear-Liquid level control
Equal percentage-Pressure & Flow control

50

Why Characterization?
To compensate the process gain changes so that loop gain
remains independent of load.
To provide uniform control loop stability over the expected range
of operations.
To match the valve gain to the system gain for optimum
performance.
Characteristics methods:
Trim shaping
Positioner characterization
Controller characterization
51

Valve Characteristics

52

Quick opening
Inherent flow characteristic with high flow at initial % of travel.
High and constant gain at initial half of its travel.
Decreasing gain at travel above 70%

53

Equal percentage
Equal increments of change in valve travel produce equal
percentage changes in the existing flow coefficient
Provides low valve gain at low percentage of valve travel, and
high valve gain at higher percentage of valve travel

54

Linear Characteristics

Flow is a linear function of travel

Gain remains constant throughout the travel i.e 1

55

Cage Shapes

Quick opening

Linear

Equal percentage

56

Plug Shapes

57

Plug Shapes

58

Plug Shapes

59

Inherent Characteristics
Relationship between flow rate and valve travel, under
constant pressure drop conditions
Inherent valve characteristics can be Quick opening,
Linear, Equal percentage

60

Inherent Characteristics
u Flow at constant pressure drop

61

Installed Characteristics

Relationship between flow rate and valve travel, under actual

process conditions
Installed flow characteristics is process dependent where
pressure drop changes with process variable

62

Installed flow Characteristics

u Flow at varying pressure drops

63

Valve Gain
Ratio of change in flow to change in stem travel

Valve Gain =

64

Guidelines for selection of Valve

Characteristic

65

Non Linear Process

At Low flow, change in input signal will cause large change in

flow-rate.
At high flows, the change in input signal will cause very small
change in flow-rate
Impossible to tune controller for stability as the controllability
and the operating range sometimes is out of boundaries

66

Compensation- for Non linear process

To provide linear gain over entire system, in a non linear
process, equal percentage characteristic is chosen.
The Equal Percents low gain compensates for high gain at
low flow
Similarly, the Equal Percents high gain Compensates for
low gain at high flow

67

Application guidelines
PROCESS

APPLICATION

GUIDELINES

Pressure

Liquid process

Equal Percent

Gas, Small volume

Equal Percent

Gas , Large volume

Max dP < 5X Min dP

Linear

Gas , Large volume

Max dP > 5X Min dP

Equal Percent

Temperature

Most

Equal Percent

Flow

Load changes

Equal Percent

Set point changes

Linear

Max dP<5X Min dP

Linear

Max dP>5X Min dP

Equal Percent

Constant dP

Linear

Liquid Level
Back Pressure

68

Body/Bonnet material carbon steel body

Most commonly used carbon steel bodies are WCC and LCC
WCC Weldable Carbon steel Cast

Can be used between -29 to 427 deg

Above 427 deg C graphitization can occur
Preferable to killed carbon steel

69

Body/Bonnet material carbon steel body

LCC Low temperature carbon steel cast
Same chemical composition as WCC
Quenched and tempered in order to meet impact requirement
Can be used between -46 to 343 deg C
Impact tested for confirming suitability

70

Body/Bonnet material Alloy steels

Addition of Chromium and molybdenum enhances the resistance
to graphitization and tempering at elevated temperature
WC6 : -29 to 593 deg C
WC9 : -29 to 593 deg C

71

Body/Bonnet material Stainless steel

For increased high temperature capability and for increased
pressure retaining capability, Alloys with still more chromium and
molybdenum are specified
To avoid sensitization (formation of carbides) carbon content is
kept low in stainless steel
CF8M, CF3M, CG8M, CF8C

72

P&ID symbols of various control valves per ISA S5.1

73

Applicable codes and standards

ASME B16.34 - valves - flanged, threaded and welding ends

ASME B1.20.1 - Pipe threads

ANSI FCI 70-2 - Control valve seat leakage

ISA 71.01 - Environmental conditions for process measurement & control

systems: Temperature and Humidity

ISA 75.01 - Flow equation for sizing control valves

ISA 75.03 - Face to face dimensions for flanges globe-style control valve bodies

ISA 75.04 - Face to face dimensions for flangeless control valves

ISA 75.17 - Control valves aerodynamic noise prediction

74

Applicable codes and standards

NEMA ICS 6 - Enclosures for Industrial controls and systems
IEC 529 - Specification for degree of protection provided by enclosure
NFPA 70 - National electric code

75

Major vendors
Valve Assembly

Actuators
= EIM

Masoneilan Dresser

= Bettis

Fisher

= Keystone

Flowserve (Valtek)

= Automax

Tyco

= Rotork

Instrumentation Limited

= Limitork

Metso

76

Thank You !

Questions?

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