TRAINING MANUAL - INSTRUMENTS DOC No.

: 29040-IC-UFR-0017

Rev. : R0
GLOBE CONTROL VALVE
Uhde India Limited Page :1

CONTENTS
Page
0.0 Cover Sheet 1
1.0 Introduction 2
2.0 Advantages of Globe Design 2
3.0 Types Of Trim 2-3
4.0 Body Materials 3
5.0 Valve Bonnets 3
6.0 Valve Packing Materials 3-4
7.0 Actuators 4
8.0 Positioners 4-5
9.0 Flow Characteristics 5-6
10.0 General Guidelines 6-7
11.0 Rangeability 7
12.0 Flashing & Cavitation 7-8
13.0 Choked Flow 8
14.0 Methods to Eliminate Cavitation 8-10
15.0 Control Valve Noise 10
16.0 Sources of Valve Noise 10
16.1 Mechanical Vibration 10-11
16.2 Aerodynamic Noise 11
16.2.1 Noise Reduction 11-12
16.3 Hydrodynamic Noise 12
17.0 Globe Control Valve Sizing 12
18.0 Preparation of Enquiry Specifications 13
19.0 Offer Evaluation 13
20.0 Inspection Of Control Valves 14
21.0 Control Valve Installation 14

Annexure: Slides 47 sheets

Applicable Revision:
Prepared: Checked: Approved:

Date: Date: Date:

First Edition: R0
Prepared: Checked: Approved:

V PADMALATA M.B. JOSHI N.C. JAIN

Date: Date: Date:
File Name: Globe.doc Server: KUMUS 206

Directory: /opt/scribd/conversion/tmp/scratch6668/50071177.doc
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1.0 INTRODUCTION
A control valve is a final control element, which regulates the rate of fluid flow as the position of
the valve plug, or disc is changed by the force from the actuator.

To do this, the valve body must

• contain fluid without external leakage

• have adequate capacity for the intended service
• be capable of withstanding erosive, corrosive and temperature influence of the process
• incorporate appropriate end connections to mate with adjacent pipelines
• have actuator attachment means to permit transmission
of actuator thrust to the valve plug stem

In a control circuit, the following are the tasks the control valve has to perform:

• Vary flow rates within a process dependent range from

maximum flow to minimum flow
• Produce an installed flow characteristic which is as linear
as possible in order to ensure that controller action is consistent over the entire control range
• Close or open quickly in the event of actuator power source failure and rapid regulation,
free of overshoot when short stroking times are required
• Reliable and long service life when carrying corrosive,
abrasive, cavitating and vaporizing fluids.

2.0 ADVANTAGES OF GLOBE DESIGN

• Simplicity of spring/diaphragm actuator.

• Availability of wide range of valve characteristics
• Low likelihood of noise and cavitation
• Availability of a wide variety of specialised designs for
corrosive, abrasive and high/low temperature and pressure applications
• Linear relationship between control signal and valve stem
movement
• Small amounts of dead band and hysterisis in operation

TYPES OF TRIM

Single Seated

Single seated valves are available in a wide variety of configurations, including special purpose
trims, have good flow shut off capability, are less subject to vibration due to reduced plug mass
and are generally easy to maintain.

They are generally top guided .Top guided valves have one less closure subject to leakage
compared to top & bottom guided valve. Also, the valve plug mass is reduced, which increases
the natural undamped frequency of the trim thus making it less susceptible to vibration. It also
allows a somewhat higher flow capacity than top and bottom guided valves for a given orifice size.

Top guided valves provide more streamlined flow and are less subject to fouling.

Double Seated

Double seated valves are much larger and heavier as compared to single seated valves.

Shut off is poor since it is not possible to have both plugs contact the seat at the same time.

Advantage of double seated valves is that the hydrostatic forces acting on the upper and lower
plugs tend to cancel each other. This reduces the actuator size required.
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However, the upper and lower plug diameters are different (to allow withdrawal of smaller plug
through larger port) which contributes to the unbalanced condition. Complete cancellation of these
forces is not possible due to hydrodynamic effects of the fluid that passes the plug contour at high
velocity. Fluid passing the lower seat (tending to close the plug) has a tendency to “suck” the plug
into seat thereby creating a dynamic imbalance between this force and the differential pressure
acting across the upper plug area.

Top and bottom guided valve has similar limitations as a double seated globe valves.

Cage Type

Advantage of these types of valves is easy trim removal because of the absence of internal
threads, which could corrode and make the removal of the trim difficult.

Variety of trim types like reduced noise trims, anti-cavitation trims can be installed and the overall
design is very rugged.

Noise level is low in cage guided valves and lower size actuators are required.

4.0 BODY MATERIALS

Valve body materials have to be chosen taking into consideration temperature, pressure ad
process compatibility.

However, for all practical purposes, we have to proceed on the same lines as the details given in
the piping specifications.

5.0 VALVE BONNETS

Extension bonnets are used for either high or low temperature service to protect valve stem
packing from the extreme temperature of process so that the packing temperature remains within
the recommended range. However, nowadays, standard bonnets of most manufacturers cater to
some extent of the negative temperature range also. It should be borne in mind that if the
manufacturer claims that their standard bonnet is suitable for a negative temperature upto say for
example –10°C and if the operating temperature is –9°C, then we should insist on extended
bonnet based on our past experience. In other words, a tolerance of 10° shall be considered. In
the above example, even for a temperature of 0° C, extended bonnet should be considered.

For high fluid temperatures typically above 200°C, radiation fin bonnet is used to provide sufficient
radiating heat loss. Bellows seal bonnets are used when no leakage along the stem can be
tolerated. They are often used when the process fluid is toxic, volatile, radioactive or highly
expensive..

One basic disadvantage of bellows seal is their relatively low-pressure ratings. The pressure
ratings decrease with an increase in valve size. Typical ratings are 10.5 kg/cm2(g) at 315° C.

6.0 VALVE PACKING MATERIALS

The purpose of packing materials is to prevent leakage of process fluid past the surface of
the valve stem.An ideal packing provides a tight seal while contributing little friction
resistance to stem movement.Screwed packing is not permissible with highly corrosive
fluids.High vacuum service requires double packing of inverted V- rings.

Teflon Packing
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Most common is teflon rings.

For higher temperature/pressure applications it can be “loaded” upto 25% with other materials to
improve its resistance. Most common material used is glass fibre and resulting packing ring is
called GF teflon. Other materials are silica and carbon.

Teflon can be used upto a maximum temperature of 450°F (230°C) in plain bonnet.

In the GF version in extended bonnet max temp limit is 850°F (455°C).Lower temperature limit is –
300° F (-185°C)

Teflon packing does not require lubrication due to its extremely low friction characteristic.

Standard PTFE packing system is very common because it:

- has low friction

- is chemically inert
- makes a tight seal
- has constant loading
- has long cycle life

Disadvantage of solid teflon packing are its high co-efficient of thermal expansion particularly near
room temperature and requirement for extra fine surface finishes to prevent undue friction and
wear of teflon rings.

Braided Asbestos

Braided asbestos can be made as split rings, which can be wrapped around valve stem, thus
facilitating maintenance when valve is installed. It employs mica or graphite for lubrication
particularly in high temperature service.

Maximum temperature limit is 1000 F (540°C) with use of radiation bonnets, it can be used at a
higher temperature.

Graphite

Graphite is chemically inert except when strong oxidizers are handled. It has low coefficient of
friction, high temp capability upto 1000°F (540°C) and lower limit of 0 F (-18°C). Disadvantages
are high stem friction and hence difficulty in loading the packing to give an effective stem seal.

7.0 ACTUATORS

In the catalogues of vendors like IL, MIL there is a table showing the maximum differential
pressures for different actuator models corresponding to a particular valve size and its rated Cvs.
In such cases, the values are compared with the shut off pressures mentioned in the specification
sheet and the actuator model is chosen in such a way that the max differential pressure is greater
than the shut off pressure mentioned in the specification sheet.

8.0 POSITIONERS

The positioner measures the valve stem position (to within 0.1 mm), compares that measurement
to its setpoint (the controller output signal) and, if there is a difference, corrects the error.

A positioner amplifies the controller signal to the extent required for the actuator spring.

The main purpose of a positioner is to guarantee that the valve moves to the position where the
controller wants it to be. The addition of a positioner can correct for many variations including
changes in packing friction due to dirt, corrosion or lack of lubrication, variation in the dynamic
forces of the process, sloppy linkages(dead band) or non-linearities in the valve actuator.
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Additionally, the positioner can allow for the split ranging the controller signal between more than
one valve, can increase the actuator speed or thrust by increasing the pressure and/or volume of
the actuator air signal.

9.0 FLOW CHARACTERISTICS

Inherent flow characteristics

Inherent valve characteristics:

The inherent valve characteristics of a control valve describes the relationship between the
controller output signal received by the actuator and the flow through that valve assuming that:

1. the actuator is linear (valve travel is proportional to the controller output)

2. the pressure difference across the valve is constant
3. the process fluid is not flashing, cavitating and there is no choked flow.

LINEAR FLOW CHARACTERISTICS:

A valve with linear characteristic produces flow rate directly proportional to the valve plug travel
throughout the travel range.

Valves with linear characteristics are often specified for liquid level control and for flow control
applications requiring constant gain.

EQUAL PERCENTAGE FLOW CHARACTERISTICS:

A unit change in lift will result in a change in flow which is a fixed percentage of the flow rate at
that lift. The change in flow rate will be small when the valve plug is near the seat and relatively
high when the valve plug is nearly wide open.

Valves with equal percentage characteristics are used on pressure control applications, on
applications where a large percentage of the pressure drop is normally absorbed by the system
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itself with only a relatively small percentage available at the control valve and on applications
where highly varying pressure drop conditions can be expected.

QUICK OPENING FLOW CHARACTERISTICS:

A valve with quick opening flow characteristics provides a maximum change in flow rate at low
travels. The curve is linear through the first 40% of valve plug travel, then flattens out noticeably to
indicate little increase in flow rate as travel approaches the wide open position. Control valves with
quick opening flow characteristics are often used for on/off applications where significant flow rate
must be established quickly as the valve begins to open.

10.0 GENERAL GUIDELINES

The following are the general guidelines for the selection of the valve characteristics.

However, in practice, very often, the characteristics to be chosen are clearly specified by the
licensor. If not, as a thumb rule, where most of the pressure drop in the system is across the
control valve, which is generally the case with level control valves, valves with linear
characteristics are chosen.

On the other hand, where relatively small % of the pressure drop is available across the valve and
where highly varying pressure drop can be expected, valves with equal percentage characteristics
are chosen.

In cases where the vendors cannot offer the customer specified characteristics, the same
is achieved through modification of the positioner cam. This should not be accepted as far
as possible since at site, very often the positioners of valves are interchanged and the
modified characteristics could create confusion.

Liquid Level systems

Application Best Inherent Characteristic

Constant ∆P Linear
Decreasing ∆P with increasing load, Linear
∆P at max load > 20% of minimum
load ∆P
Decreasing ∆P with increasing load, Equal percentage
∆P at max load < 20% of minimum
load ∆P

Increasing ∆P with increasing load, Linear

∆P at max load < 200% of minimum
load ∆P

Increasing ∆P with increasing load, Quick opening

∆P at max load > 200% of minimum
load ∆P

Flow Control Processes

Flow measurement Location of BEST INHERENT CHARACTERISTIC

Signal to controller Control valve
In relation to Wide range of flow Small range of flow but
Measuring Set point Large ∆P change at
element Valve with increasing
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Load

Proportional to flow In series Linear Equal percentage

In bypass* Linear Equal percentage
Proportional to flow In series Linear Equal percentage
Squared
In bypass* Equal percentage Equal percentage
* When control valve closes, flow rate increases in measuring element

Pressure Control Systems

Application Best Inherent Characteristic

Liquid Process Equal Percentage
Gas Process, Small volume, less than 10 ft pipe between control Equal percentage
Valve and load valve.
Gas process, large volume(process has receiver, Linear
Distribution system or transmission line
Exceeding 100 ft, decreasing ∆P with increasing load,
∆P at max load>20% of min load ∆P
Gas process, large volume, decreasing ∆P with Equal percentage
Increasing load, ∆P at max load<20% of min load ∆P

11.0 RANGEABILITY

Rangeability is defined as the ratio between maximum and minimum “controllable” flow.
Typical rangeability of a globe control valve is 50:1.

12.0 FLASHING & CAVITATION

Cavitation and flashing tend to limit the flow through the control valve in many common
applications and therefore must be taken into account for sizing a valve accurately.

These two phenomena represent actual changes in the fluid media. The change is from liquid
state to vapor state and results from increase in fluid velocity at or just downstream of the greatest
flow restriction, normally the valve port.

As liquid passes through the restriction, the minimum cross sectional area occurs just downstream
of the physical restriction at a point called the vena contracta.

To maintain a steady flow through the valve the velocity is greatest at the vena contracta and this
increase in velocity is accompanied by a decrease in pressure a the vena contracta.

Further downstream, as the fluid stream expands into a larger area, velocity decreases and
pressure increases. But, of course, downstream pressure never recovers completely to equal the
pressure that existed upstream of the valve. The differential pressure that exists across the valve
is a measure of the energy that was dissipated in the valve.

If pressure at the vena contracta should fall below the vapor pressure of the fluid(due to increased
velocity at this point) bubbles will form in the flow stream. Formation of bubbles will increase
greatly as the vena contracta pressure drops further below the vapor pressure of the liquid.

If pressure at the valve outlet remains below the vapor pressure of the liquid, the bubbles will
remain in the downstream and the process is said to have flashed.
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Flashing damage is normally greatest at the point of highest velocity, which is usually at or near
the seat line of the valve plug and seat ring.

On the contrary, if downstream pressure recovery is sufficient to raise the outlet pressure of the
liquid, the bubbles will collapse or implode, producing cavitation.

As the pressure drops at constant temperature, vapor molecules agglomerate until spontaneous
generation of bubbles of critical size occurs due to meetings of the vapor molecules in large
enough quantities to overcome surface tension. These bubbles serve to nucleate further
evaporation. When the bubble is larger than the critical diameter, the process becomes
exothermic and the bubble tends to grow in size without further external energy input. Energy
associated with the forces of nucleation must be transferred to the bubble to make it grow to the
critical diameter but the bubble will give up energy while growing beyond that diameter.

As the pressure is recovered beyond the vena contracta, the surface tension force dominates and
further collapse becomes spontaneous. When the bubble implodes, it appears to form a torus with
a tiny central jet into which the entire energy of the bubble is concentrated. This creates an
extremely high pressure over a very small area whenever the jet impinges against a solid surface.

If the bubbles collapse in close proximity to solid surfaces in the valve, the energy released will
gradually tear away the material leaving a rough cinderlike surface.

Cavitation is usually coupled with vibration and a sound like rock fragments or gravel flowing
through the valve.

The pressure recovery in a valve is a function of its particular internal construction. In general, the
more streamlined a valve is, the more pressure recovery is experienced. This means increased
possibility of cavitation.

13.0 CHOKED FLOW

Apart from the physical damage due to cavitation and flashing, formation of vapour bubbles in the
liquid flowstream causes a crowding condition at the vena contracta, which tends to limit flow
through the valve. So, while the basic liquid equation implies that there is no limit to the flow
through the valve as long as the differential pressure across the valve increases, in reality, if valve
pressure drop is increased slightly beyond the point where bubbles begin to form, a choked flow
condition is reached. With constant upstream pressure, further increases in pressure drop (by
reducing downstream pressure) will not produce increased flow through the valve.

In high recovery valves, since pressure drop is higher as compared to low recovery valves and
hence there is increased possibility of cavitation.

14.0 METHODS TO ELIMINATE CAVITATION

• USE OF MATERIALS WITH HIGHER HARDNESS

Stelliting is the process where a harder material is deposited on the plug and seat. However,
cavitation damage is not eliminated by stelliting, it is only lessened.

The best overall selection for cavitation resistance is Stellite 6B (28% chromium, 4% tungsten, 1%
carbon, 67% cobalt). Stellite 6 is used for hard facing of trims and has the same chemical
composition but less impact resistance. However, if there are traces of amines in the process
cobalt cannot withstand the effect of amines and hence 17-4 pH is used as trim material.

• REVISED PROCESS CONDITIONS

A reduction of operating temperature can lower the vapour pressure sufficiently to eliminate
cavitation.
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Similarly, increased upstream and downstream pressures, with ∆P unaffected, or a reduction in ∆P

can both relieve cavitation. Therefore, control valves that are likely to cavitate should be installed
at the lowest possible elevation in the piping system and operated at minimum ∆P. Moving the
valve closer to the pump will also serve to elevate both the upstream and downstream pressures.

If cavitating conditions are unavoidable, then it is preferred to have not only cavitation but also
permanent vaporization(flashing) through the valve. This can usually be accomplished by a slight
increase in operating temperature or by decreasing the outlet pressure. Flashing eliminates
cavitation by converting the incompressible liquid into a compressible mixture.

• The multistep valves can avoid cavitation by replacing a single and deep vena contracta,
as would occur in a single port valve, with several small vena contracta points as the pressure
drop is distributed between several ports working in series.

GAS INJECTION

Another valve design variation that can alleviate cavitation is based on the introduction of non-
condensable gases or air into the region where cavitation is anticipated. The presence of this
compressible gas prevents the sudden collapse of the vapour bubbles as the pressure recovers to
values exceeding the vapour pressure and instead of implosions, a more gradual condensation
process occurs.

The gas may be admitted through the valve shaft or through downstream taps on either side of
the pipe, in line with the shaft and as close to the valve as possible. Since the fluid vapour
pressure is usually less than atmospheric, the air or gas need not be under pressure.

• REVISED INSTALLATION

In order to eliminate cavitation, it is possible to install two or more control valves in series.
Cavitation problems can also be alleviated by absorbing some of the pressure drop in restriction
orifices, chokes,(downstream to the valve)or in partially open block valves upstream or
downstream to the valve.

Choke is a simple and effective restriction having a rounded entrance and a long, straight throat
that can be discharged into a larger volume. Vaporization of a liquid increases the volume
tremendously and creates high velocities. So does the evolution of gas from a liquid. The fluid can
be discharged through a choke into a pool of liquid where the energy of the high velocity jet
stream will be absorbed.

Corrosion Resistance of Various Materials to Cavitation

Trim/valve body Relative cavitation Corrosion

Cost
material Resistance index Resistance
Carbon steel, WCB 60 Fair Low
SS316 160 excellent Medium
SS410 200 good Medium
K-Monel 300 excellent High
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SS, type 17-4 pH 340 Excellent medium

SS440C 400 Fair High
SS329,annealed 1000 excellent medium
Stellite#6 3500 excellent Medium
Stellite#6B 3500 excellent high

15.0 CONTROL VALVE NOISE

The U.S. Occupational Safety and Health Act of 1970 established maximum permissible noise
levels for all industries whose business affects interstate commerce and these have become the
accepted noise standards for most regulatory agencies.

Permissible Noise Exposures

Duration per Sound level

Day / Hr. dBA

8 90
6 92
4 95
3 97
2 100
1-1/2 102
1 105
½ 110
¼ or less 115

Decibels (dB) are a measure, which gives an indication of loudness. The “A” added to the term
indicates that correction accounting for the response of the human ear has been made. The
sensitivity of our ears to sounds varies at different frequencies. Applying this correction is
called “A” weighting and the corrected noise level is given in dBA.

The A weighting factor at any frequency is determined by how loud a noise sounds at that
particular frequency compared to the apparent loudness of sound at 1000 Hz. At 1000 hertz, the
A-weighting factor is zero so if the sound pressure level is 105 dB, we say it sounds like 105dB

16.0 SOURCES OF VALVE NOISE

The major sources of valve noise are:

• Mechanical vibration of valve components

• Hydrodynamic noise
• Aerodynamic noise

16.1 Mechanical Vibration

It is caused by the response of internal components within a valve to turbulent flow through the
valve. Turbulent flow impinging on components of valve can induce vibration against neighbouring
surfaces. If this turbulence induced vibration of trim parts approaches a natural frequency of the
plug-stem combination, a case of resonance will exist and this can result in fatigue failure of the
trim parts.

Noise from mechanical vibration does not occur often in control valves, especially since the
introduction of top and cage guided valves.

There is presently no reliable method for predicting noise generated by mechanical vibration in
control valves.
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16.2 Aerodynamic Noise

Aerodynamic noise is a direct result of conversion of mechanical energy of the flow into acoustic
energy as the fluid passes through the valve restriction.

High intensity levels of noise resulting from turbulent flow are more common to valves handling
gas than to those controlling liquids. Noise resulting from turbulent flow of a gas is called
aerodynamic noise.

Sources of turbulence in gas transmission lines are: obstructions in the flow path, rapid expansion
or deceleration of high velocity gas and directional changes of the fluid stream. Specific areas that
are inherently noisy are: headers, pressure regulators, line size expansions and pipe elbows.

16.2.1 Noise Reduction

It can be achieved by either source treatments(preventing noise generation) or path treatments

(pipe insulation, silencers or increase in pipe schedule). Since, sound once generated, propagates
virtually unattenuated in downstream pipe, source treatment becomes the preferable method.

A. Source Treatment

Noise is the high energy vibrations due to high velocity of fluid inside the control valve. Basically,
noise reducing methods aim at reducing the high velocity of the fluid.

There are two methods for reduction of noise:

• Reduction of size of fluid jets by use of multihole cage trims

and consequently, reduction of fluid velocity.

• Another method is to let the fluid pass through a number of

restrictions providing a flow pattern dissipating energy through high headloss.

B Path Treatment

There are three methods of incorporating path treatment into control valve systems:

• Silencers are effective provided they are installed directly

downstream of the valve. But there are some technical problems. Firstly, to be effective, they
require low flow velocities so their use is impractical especially in high capacity systems.
Secondly, the acoustic elements are not always compatible with the flowing medium.

• An increase in the wall thickness of downstream piping

is an effective method. However, since noise once generated does not dissipate rapidly with
downstream pipe length, this method must normally be used throughout the downstream
system.

• Pipe insulation is an effective means to reduce radiated

noise.

Insulation must be used throughout the downstream system. The material must be carefully
installed to prevent any “voids” which could reduce the effectiveness. Thermal insulation
normally used on piping systems is limited in its effectiveness in reducing noise. More suitable
materials are often not acceptable at high temperature since their binders may burn out
radically changing their acoustical and thermal qualities.

16.3 Hydrodynamic Noise

The major source of hydrodynamic noise (noise resulting from, liquid flow) is cavitation.
Methods to counter cavitation have already been covered earlier.
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17.0 GLOBE CONTROL VALVE SIZING

A valve too small will not pass the required amount of flow. A valve too large will be unnecessarily
expensive and may create instability problems as it attempts to control at very low increments of
travel.

So, proper sizing of control valve is very much essential.

Bernoulli discovered that as liquid passes through an orifice, the square of the fluid velocity is
directly proportional to the pressure differential across the orifice and inversely proportional to the
specific gravity of the fluid. Therefore, the greater the pressure differential, the higher the velocity;
the greater the density, the lower the velocity.

Q=CV √ ▲P/G
Where Q= capacity in gallons

Flow Coefficient Cv:

It is the number of U.S. gallons per minute of water which will pass through a given flow restriction
with a pressure drop of 1psi.

Cv CALCULATIONS
▲Pv<P1/2 P2>P1/2 ▲Pv>P1/2 P2<P1/2
Liquid CV 1.17V√ρ/▲Pv 1.17V√ρ/▲Pv
Gas 1.17Vn/514√(ρnT/▲PvP2) 1.17Vn/(√ρnT)/257P1

Steam/Vapor 1.17m/31.6√(V2/▲Pv) 1.17m/31.6√(2v2*/P1)

Saturated /wet steam 1.17m/31.6√(V2X/▲Pv ) 1.17m/31.6√(2V2 *X/P1 )

Where
V liquid m3/hr
Vn gas m3/hr
M steam kg/hr
P1,P2,∆Pv bar
ρ spec gravity of liquid kg/l
ρn density of gas at NPT Nm3/hr
V2 spec volume of steam at P2 m3/kg
V2* spec volume of steam at P1/2 m3/kg
T operating temperature in deg K
X % moisture in steam

For flashing services, calculate Cv of the liquid portion and gas portion and consider the sum for
valve sizing. This is to ensure that the valve will be able to pass both the liquid and vapor
volumes.

18.0 PREPARATION OF ENQUIRY SPECIFICATIONS

• Line size should be specified correctly. Normally, the

valve size is one size lesser than the line size but never less than half the line size. If line size
is not specified correctly, then it results in incorrect valve sizing.
• Process data should be checked thoroughly for
correctness to be able to get the right size of valve.
• Flange connection should be specified correctly for it to
match with the piping flange. So also for the rating to be able to bolt the valve with the piping
flange.
• Body and trim material should be compatible with the
process fluid.
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• Bonnet type should take into account the operating

temperature. Finned bonnets to be specified for temperatures above 200° C.
• Minimum actuator sizing pressure is very important since
the actuator has to work satisfactorily even if the air pressure falls to the specified minimum
pressure.
• All accessories have to be specified. If flameproof
instruments are required, the same have to be ensured.
• IBR , NACE and other certifications, radiography
requirements(if mentioned in the piping specifications) as required to be specified.

19.0 OFFER EVALUATION

• As emphasised above, the materials, flange rating and

connection type, bonnet type should be checked.
• Similarly, certifications have to be checked
• Check Cv calculations specifically for the correctness of
process data considered. In equal percentage valves, the normal opening should be around
60-70% and maximum opening should be around 85%. In linear valves, the normal opening
should be around 40-50% and maximum should be around 60-70%.
• Check if both liquid and vapor phases have been
considered for sizing in flashing services. In case of cavitating services, check whether anti
cavitation trims have been offered. It has been noticed that very often, vendors have to be
specifically asked to quote for anti cavitation trims specifically.
• Ask vendors to calculate noise levels and if situation
demands, whether low noise trims have been ofered or not.
• Accessories like limit switches, solenoid valves, AFR,
volume boosters, air lock relays etc. have to be checked in the offer
• Very often vendors confirm their ability to give Cvs not
listed in their catalogues to bag the order and later express their inability to give the same.
Then we are forced to compromise in terms of the available Cvs. So caution has to be
exercised in accepting non standard Cvs.
• The same problem cited above holds good even for non
standard actuator spring ranges. As an example there was a case where, as per the catalog,
the suitable spring range was 0.9-4 kg/cm2 and the required air supply was 4kg/cm2. But
since our minimum actuator sizing pressure was 4 kg/cm2, vendor confirmed to offer a spring
range of 0.9-3.5 kg/cm2 with air supply of 4 kg/cm2. Such modification should not be
accepted.
• Sometimes to meet the actuator air requirement, pilot
operated solenoid valves are offered. These are not to be accepted since problems are likely
in their performance.
• Check if Cv testing for valves with Cv<1 has been offered
or not to avoid commercial implications after order placement.
• Solenoid valve orifice shall be minimum 2.5mm to avoid
choking. However, vendor should size the orifice to cater to the stroking time requirements
mentioned in the General Specifications for control valves or in the data sheets in case of any
special requirement.

20.0 INSPECTION OF CONTROL VALVES

• Perform 100% visual check for correctness of tag no.,

face-face dimensions of valve, flange dimensions, tagplate(showing the rated Cv, air failure
position, flow characteristics, leakage class, spring range),painting, etc. The face to face
dimensions of a valve should be matching with those mentioned in the vendor drawings since
the same are forwarded to the piping department.
• Check for IBR stamp on the valve as specified
• Check for correctness of positioner calibration.
 TRAINING MANUAL - INSTRUMENTS DOC No. : 29040-IC-UFR-0017

Rev. : R0
GLOBE CONTROL VALVE
Uhde India Limited Page : 14

• Check for satisfactory operation of accessories like

solenoid valve, limit switches, etc.
• Perform hydrostatic test, seat leakage test and
pneumatic test on actuator
• Perform Cv testing if specified
• Chek all the test certificates for their correctness.

21.0 CONTROL VALVE INSTALLATION

Globe valves and other linear motion types should be installed vertically, with the actuator above
the valve. In this position there is less bending moment and stress at the bonnet connection.
Although it is definitely not recommended, if the valve must unavoidably be installed horizontally,
the actuator must be supported suitably..

In a linear motion valve, if the valve is mounted upside down with the actuator below the packing
box, there is possibility of leakage if there is lubricating oil. It may be difficult to mount even the
accessories. If control valves have to be installed in vertical lines, it is necessary to inform the
valve vendors so that orientation of i/p converter, AFR, actuator can be accordingly taken care of.

It is better for the valve to be located where it will perform so that maintenance is a rare event than
to have it located for easy access but frequent failure. It is better to build an access platform at the
valve than to risk a disaster or even frequent downtime and maintenance.

Because pipes move and even vibrate it is important that the air tubing, hydraulic lines and
electrical connections to actuators be sufficiently flexible.

The location of the valve shall be such that water or other drippings cannot enter the enclosure
and the valve can be easily accessed for maintenance purpose.

There must be adequate clearance at the adjacent fitting for the flange bolts to be installed.

The bypass valve should not be mounted just above the actuator since any leakage would result
in damage to the actuator and other accessories by spilling of the fluid.