Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
Control valves
The final control element is the last element of the closed control loop that implements the
control action. It receives the output signal (control or actuating signal) from a controller and
adjust accordingly the value of the manipulated variable by changing the amount of matter or
energy entering the process. The following definition of a control valve (from Process
Instruments and Controls Handbook, Ed. by Considine D.M., McGraw-Hill Book
Company, 1985, p. 19.4) is used by the Scientific Apparatus Makers Association (SAMA):
Control valves are used primarily to throttle energy in a fluid systems and not only for shut-
off purposes. Their internals must withstand high fluid velocity and turbulence for long
periods without maintenance.
Figures 10.1 and 10.2 shows a schematic design of a pneumatic valve. This valve is an air-
operated device which controls the flow through an orifice by positioning appropriately a
plug. In other words, it is a variable orifice in a line.
The plug 1 is placed in the orifice 2 of the valve and attached to the end of the stem 3. The
orifice is placed inside the body of the valve 4 made of cast iron, alloy steels, alloy steels plus
corrosion-resistant alloys, or bronze. The upper part of the final control element is an actuator
5. A diaphragm 6 divides this actuator in two chambers. The upper end of the stem is
supported on the diaphragm. When the air pressure (the output signal from a pneumatic
controller) above the diaphragm increases, the diaphragm deflects and the stem moves
downwards thus restricting by the plug flow of the fluid through the orifice. This type of a
pneumatic valve is called “air-to-close” valve. When the air pressure goes down the stem
under the action of a spring 7 will move upwards, thus opening the orifice. There is another
type of valves, which operate in opposite action, ie, when the air pressure increases the plug
opens the orifice. Such valves are called “air-to-open” valves. If the air pressure varies from
20 to 100 kPa the plug is moved from a fully open to fully closed position.
10.3. Actuator
This is a mechanism that physically opens or closes the valve. The actuator is an intermediate
device between the convereted control signal and the final control element.
1 1 1 1
Air in
1
1
1 1 1 1
• inertia forces;
• static friction forces;
• thrust forces caused by weight and unbalanced fluid pressure.
Valve positioner (Figure 10.3) is a control device designed to impart sensitivity to the valve
and to enshure accurate positioning as dictated by a control signal.
Controlled
Load changes -
variable - valve
stem/gland friction
stem position
Position set and hysteresis,
Valve
point process pressure
from main variation
controller output
Output
+ Pneumatic +
pressure
Position valve
control
controller actuator
- element +
Position
detector
Mechanical feedback
link of valve stem
position
• ball valves;
• butterfly valves;
• diaphragm valves;
• gate valves;
• plug valves.
• the pressure of the liquid when passing through the valve can fall down to the vapor
(saturating) pressure of this liquid, Pvapor, at the current temperature. In this case liquid
(say, water) starts to boil with the formation of bubbles, which collapse and condense
while flowing downstream to the zone of higher pressures (P2’ and P2). This collapse
of bubbles develops localised pressures of up to 690 MPa. This undesired
hydrodynamic phenomenon which is called cavitation causes rapid wear of the valve
trim, valve body and outlet piping, develops severe noise and vibration.
• the pressure of the gas when passing through the valve can fall down to its critical
pressure. This will cause gas sonic velocity. As a result vibration and severe noise are
developed.
P1
P1 ’
Non-critical flow ∆P.
P1 ’ ∆Pcrit.
Critical flow
P1
P1 min. P1 crit.
Pvapor.
Figure 10.5. Variation of the fluid pressure when passing through a control valve.
The constant of the valve for conditions of flow can be determined experimentally for various
conditions. The differential pressure across the valve can be calculated from the analysis of
the decreasing of pressure along the pipes (hydraulic gradient method). Thus evaluated valve
flow coefficient is used for selection of the desired type of the valve from the tables for
standard valves.
As the liquid passes the point of greatest restriction inside the control valve, its velocity
reaches a maximum and its pressure falls to a minimum. If the pressure falls below the
liquid’s vapor pressure, vapor bubbles form within the valve. Increasing the pressure drop
across the valve beyond this point where vapor bubbles form has no effect on the flow. The
pressure drop at which choked flow begins is called the terminal pressure drop.
10.6.2. Flashing
If the pressure downstream of the valve is below the liquid’s vapor pressure, the vapor
bubbles persist in the liquid. This is flashing.
• the fluid at the inlet must be in all-liquid condition, but some vapor must be present
at the valve outlet;
• the fluid at the inlet may be in either a saturated or a subcooled condition;
• the valve outlet pressure must be either at or below the vapor pressure of the liquid.
Flashing effects:
10.6.3. Cavitation
• the fluid at both the inlet and outlet must be in all-liquid condition;
• the liquid must be subcooled state at the inlet, because if the liquid will be in a
saturated state, then any pressure drop across the valve will cause the presense of
vapor downstream;
• the valve outlet pressure must be either at or above the vapor pressure of the liquid.
Evidences of cavitation:
• noise. At fully developed cavitation it sounds like a gravel psees through the valve;
• vibration. Depend on the mass of the system, how well the system components are
anchored, whether valve-mounted instruments are vibration-sensitive;
• material damage. Damage of valve plugs, development of eroded holes through the
valve body, damage of the guiding surfaces and valve plug seating surfaces, etc.
Among theories of cavitation we can mention two which are the most eccepted:
• high pressure shock waves from the bubbles exploding in close vicinity of the solid
part of the valve strike that surfaces and destroy them.
• chemical theory suggests that when a solid surface undergoes the strike from shock
waves, temperature of these surfaces increases due to absorption of energy, and as
the result a chemical reaction between the flowing fluid and the surface material
occurs.
In order to avoid cavitation and flashing damage a maximum allowable pressure drop across
the valve must be identified:
∆Pallow , psi - the maximum allowable differential pressure for sizing purposes,
or terminal pressure drop;
Km - the valve recovery coefficient from the manufacturer’s catalogue;
P1 , psia - absolute inlet fluid pressure;
Pvapor , psia - absolute fluid vapor pressure at the inlet temperature;
The characteristic of a control valve is the relationship between the valve position and the
flowrate through the valve in the following form:
F X
= f = f ( x ) , (10.2)
Fmax X max
where,
m3
F, - fluid flowrate through the control valve;
s
m3
Fmax , - maximum fluid flowrate through the control valve;
s
X,m - stem displacement from the closed position;
X max , m - maximum stem displacement;
x - fractional stem displacement.
The inherent characteristic of a valve is obtained when there is a constant pressure drop
across the valve for all valve positions, the process fluid is not flashing, cavitating or
approaching sonic velocity (choked flow), and the actuator is linear (valve stem travel is
proportional to the controller output).
Control valves with this characteristic provide a large change in flowrate for a small change in
valve position. This characteristic is used for on/off or two-position control systems in which
the valve must move quickly from open to closed or vice versa. (see line a in figure below).
Such a valve may allow 90% of maximum flowrate with only a 10% travel of the stem.
0 .0
a b
0 .0 c d
e f
0 .0
0 .0
F/Fmax
0 .0
0 .0
0 .0
0 .0
0 .0
1 .1
1 .1 0 .0 0 .0 0 .0 0 .0 1 .1
X/Xmax
This characteristic (see line b in figure above) provides a linear relationship between the valve
position and the flowrate and is described by the following mathematical relationship:
F X
= . (10.3)
Fmax X max
This is the ideal situation when the valve alone determines the pressure drop.
F X
= = x. (10.4)
Fmax X max
Fmax
α= . (10.5)
Fmin
F
=α( x −1) . (10.6)
Fmax
This type of control valve does not shut off the flow completely in its limit of stem travel.
Fmin represents the minimum flowrate when the stem is at one limit of its travel. Line d in
the above figure shows the equal percentage characteristic for the case when α = 20 , line e
for the case when α = 50 .
A fractional change in valve stem position produces a proportional change in the valve
flowrate.
F 1
= . (10.12)
Fmax α − x(α −1)
Metric valve flow coefficient, K v , represents the flow in cubic meters per hour which can be
passed by the valve when a pressure drop across the valve is equal 1 bar.
Below are suggestions which are need to be used when choosing control valves: