Engineers India Limited

CONTROL VALVES

12/29/16

WHAT IS VALVE
Valves

are mechanical devices that controls the flow

and pressure within a system or process

Functions from Valves are:

Stopping and starting flow
Reduce or increase a flow
Controlling the direction of flow
Regulating a flow or process pressure
Relieve a pipe system of a certain pressure

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Globe valve

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GLOBE VALVE

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Gate valve

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CHECK VALVE

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CHECK VALVE

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CHECK VALVE

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BALL VALVE

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BUTTERFLY VALVE

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DIAPHRAGM VALVE

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ROTATRY TYPE ECCENTRIC PLUG VALVE

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Valve parts-TRIM
The

internal elements of a valve are collectively

referred to as a valve's trim. According to API
Standards 600, "Steel Gate Valve-Flanged and Buttwelding Ends, Bolted Bonnets", the trim consists of
stem, seating surface in the body, gate seating
surface, bushing or a deposited weld for the backseat
and stem hole guide, and small internal parts that
normally contact the service fluid, excluding the pin
that is used to make a stem-to-gate connection (this
pin shall be made of an austenitic stainless steel
material).

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Valve parts- Stuffing Box

A stuffing

box is an
assembly which is used to
house a gland seal. It is
used to prevent leakage of
fluid, between turning parts
of valves. Compression
packing is the sealing
elements in stuffing boxes.
They consist of a soft
material that is stuffed into
the stuffing box and
compressed by a gland to
form a seal around the
valve stem.
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Valve parts- Stuffing Box

A stuffing

box is an
assembly which is used to
house a gland seal. It is
used to prevent leakage of
fluid, between turning parts
of valves. Compression
packing is the sealing
elements in stuffing boxes.
They consist of a soft
material that is stuffed into
the stuffing box and
compressed by a gland to
form a seal around the
valve stem.
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Valve Components

Controls the
movements of the disc.
Support element
connection
between bonnet
Compresses
and handwheel.
packing..
The location for
packing to be
Upper part of
placed.
Directs
flow, andfor,
valve.
Support
attachment
yoke
actuator,
component
system
handwheel,
etc..
Body
to bonnetto
seal.

Gland
Packin
Flange/
g
Backseat
Follower
Stem
Gland
Flange is a
one piece unit

used to compress
The area where
packing.
disc/wedge
Follower
consists
closes
on the
of
two separate
pieces.
valve body to
Bolted
stop ororreduce
threaded.

Handwhee
Yoke
l bushing
Yoke
or stem nut
Gland
Seal between the stuffing
Stuffing
Box
box and
stem.
Transfer
motion
of between
Handwheel
Bonne
Provides
a seal
the
to the
disc.
stem
and bonnet. Keeps
Attached
to disc
by:
Split
Joint
Gasket
t
pressure
off packing
when
Threaded
Body
valve
is open.
One piece
Pins/cotter
keys. Wedge/Disc
Seat

Component part of the valve

that opens or closes against the
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seat to start or stop flow.

VALVE TEST SEQUENCE

FIRE SAFE

VALVE
ASSEMBLY

SHELL TEST

SHOP TESTING

BACK SEAT
AIR SEAT
SEAT TEST

Helium Test

Special Test
FINAL
INSPECTION

SEAT TEST
AT AMBIENT TEMP
SHELL TEST

CRYO
TESTING

VISUAL INSP.
DIM. AS PER
GA DWG

HYDRO SEAT

CLEANING
& DRYING

SEAT TEST
AT -196C TEMP

PAINTING.

CLEANING
& DRYING

SHELL TEST
TORQUE TEST

SHIPMENT.
TRACEBILITY
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CRYO TEST

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FIRE SAFE TEST

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EIL VALVE SHEET NO NOMENCLATURE

( 5 DIGITS )
EIL VALVE SHEET NO NOMENCLATURE ( 5 DIGITS )
THIRD DIGIT FOR RATING &
CAST/FORGED

FIRST TWO DIGITS

LAST TWO DIGITS

51

GATE

800 #

FORGED

1-24

CS

52

GLOBE

1500#

FORGED

25-44

AS

53

CHECK

2500#

FORGED

45-80

SS

54

BALL

150#

CASTED

81-90

EXOTIC

55

PLUG

300#

CASTED

91-99

REFER PROJECTS

56

BUTTERFLY

600#

CASTED

57

DIAPHRAGM

900#

CASTED

LAST DIGIT - 2

IBR

58

NEEDLE

1500#

CASTED

LAST DIGIT - 4

LT

2500#

CASTED

3000# - ??

CASTED

NOTE

EXAMPLES

SHEET NO

DETAILS OF VALVES

51301

GATE VALVES 150 # CASTED CS NON IBR

53152

CHECK VALVES 1500 # FORGED SS IBR

52484

GLOBE VALVES 2500 # CASTED EXOTIC MATERIAL LT NON IBR

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WHAT IS CONTROL VALVE

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WHAT IS THE USE OF CONTROL VALVE

Control valves are valves used to control conditions

such as flow, pressure, temperature, and liquid level by
fully or partially opening or closing in response to
signals received from controllers that compare a
"setpoint" to a "process variable" whose value is
provided by sensors that monitor changes in such
conditions

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CONTROL VALVES COMPONANTS

CONTROL VALVE

Valve assembly

Actuator+ Sub Assemblies( Positioner,

Limit switch, AFR, Booster relay, SOVs)

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VALVES

BODY DESIGN

SLIDING STEM VALVES

ROTARY VALVES
1) Globe valve
1) Butterfly valve
2) Angle globe vale
2) Ball valve
3) Plug valve

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Actuators

Pneumatic Actuators

Electrohydraulic Actuators

Diaphragm Actuators

Actuators types
Piston Actuators

Vane Actuators

Rack and pinon

Actuators

Electric Actuators

Gas over oil actuators

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Diaphragm Actuators

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PISTON Actuators

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VANE Actuators

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RACK AND PINION ACTUATOR

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CONTROL VALVE ACCESSORIES

POSITIONER:Positioners are most commonly used to move a control valve to a
specified position so that a process meets specific parameters (flow,
pressure, temperature).
TYPE OF POSITIONERS: Pneumatic positioners
Analog I/P Positioners
Digital controller
Digital non communicating
HART
Fieldbus

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POSITIONERS

These instruments are available in three configurations:

Pneumatic Positioners: Pneumatic positioners receive a control

signal and translates that into the appropriate pneumatic output
signal to the control valve actuator.

I/P Positioners: Electromechanical positioners are conventional

pneumatic positioners that have an additional integrated electropneumatic transducer.

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POSITIONERS

Digital Positioners:
a. Digital non communicating-A current signal (4-20 mA) is supplied to the
positioner, which both powers the electronics and controls the output.
b. HART: This is same as digital non communicating but but is also capable of
two-way digital communication over the same wires used for the analog
signal.
c. Field bus type: This type receives digitally based signals and positions the
valve using digital electronic circuitry coupled to mechanical components.
An all-digital control signal re-places the analog control signal.
Additionally, two-way digital communication is possible over the same wires.
Field bus technologies benefit the end user by enabling improved control
architecture, product quality and wiring.

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OTHER ACCESSORIES

LIMIT SWITCHES
SOLENOID VALVE
SUPPLY PRESSURE REGULATORS
PNEUMATIC LOCK UP SYSTEM
VOLUME BOOSTER

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CONTROL VALVES-TERMINOLOGY

Required Flow Capacity OR Flow Coefficient (Cv):

In general capacity refers to the amount of fluid a valve can pass through it
in a given time fully open. Because there are so many factors involved in
determining this amount, Flow coefficient is developed that can express
the valves capacity with one figure
One Cv is equal to a flow rate of one gallon per minute of water at 60
degrees F at one pound per square inch pressure differential

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CONTROL VALVE LEAKAGE

Control Valve Leakage This is basically the fluid which passes through the valve
when the valve is fully closed. This value however should
not be considered as the valve Cv at NIL Opening.
So this leakage shall depend on the contact of valve plug
& seat with the seating force applied for holding the plug
over the seat.

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CONTROL VALVE LEAKAGE

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CONTROL VALVES

STANDARDS AND SPECIFICATION:

B16.34
ISA

75-1 Selection for control valve

FCI 70-2 control valve seat Leakage
API-598 valve testing
API-607-4 Fire safe test for soft seated valve
EIL SPEC 6-51-0031 & 0037
EIL ITP 6-81-2031 & 6-81-2037
IS/IEC 60079 Equipments under Hazardous Area.

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FLOW CHARACTERISTICS OF CONTROL VALVE

Flow Characteristic of a control valve is the relationship

between the flow rate through the valve and the valve
travel as the travel is varied from 0 to 100%
Two type of characteristics are briefed as below:
Inherent characteristic-Depends on constant pressure
drop and properties are certified by the lab.
Installed characteristic: Depends when valve is in actual
operation and pressure drop is allowed to change
naturally, instead of being constant (by the varying
process conditions).

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FLOW CHARACTERISTICS OF CONTROL VALVE

Characteristic-

Linear

100
Quick
Opening

80
Cv
%
Design Cv

Inherent

60

Equal percentage
Quick opening

40
20
0
0

20

40
60
80
% Valve Travel

100

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FLOW CHARACTERISTICS OF CONTROL VALVE

Inherent

Characteristic-

Inherent valve characteristic is an

inherent function of valve flow
passage geometry and does not
change as long as pressure drop is
held constant. Many valve designs
particularly rotary ball valve,
butterfly valve and eccentric plug
valve have inherent characteristics
which can not be easily changed.
However most globe valve have a
selection of valve cage or plugs
that can be interchanged to modify
the inherent flow characteristics
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FLOW CHARACTERISTICS OF CONTROL VALVE

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Bernoullis Law
Bernoulli's principle states that for an

Incompressible flow, an increase in the speed of

the fluid occurs simultaneously with a decrease in
pressure.

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Conservation of Energy & Mass

Mass
1

Energy
2
Bernoullis Equation for
Incompressible Flow

V2 + P = Constant
V P
1A1V1 = 2A2V2
A V
Higher velocity through a
smaller area

Pressure decreases as velocity

increases
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Control Valve Fluid Mechanics

Control valves throttle

by converting
static pressure to
kinetic energy.
Pressure is reduced by
creating
resistance along the
fluids flow path.

P1
P2

Dynamic
Pressure

FL
Pvc
Letdown Path

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Conservation of Mass/Energy

Pressure P1

Velocity at Vena Contracta

Velocity V1

V2
P2
Vena Contracta Pressure

Area

A1

A2
Vena Contracta Area
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What is Cavitation?
Cavitation

is defined as the phenomenon of formation of

vapor bubbles of a flowing liquid in a region where the
pressure of the liquid falls below its vapour pressure.
Cavitation is usually divided into two classes of behavior:
inertial (or transient) cavitation and Incipient cavitation.
Inertial cavitation is the process where a void or bubble
in a liquid rapidly collapses, producing a shock wave.
Incipient cavitation is the point at where cavitation
begins, but has not reached a destructive state

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Cavitation Phenomena

Vvc

P1

Pressure
Downstream Pressure
Recovery Above Vapor
Pressure

V1

Velocity

Pvapor

Formation of
Vapor Bubbles
Flashpoint

Bubbles
Collapse

Pvc

V2
P2

Cavitation

Local Fluid Pressure Drops Below Fluid

Vapor Pressure
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What is Cavitation?

Vena Contracta

1. Local Pressure Drops Below Fluid

Vapor Pressure, Pv
2. Vapor Bubble Forms

Flow

3. Pressure Recovers Above Pv

P>Pv
P<Pv

4. Collapse of Vapor Back to Liquid

5. Addition of Turbulence & Noise

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Why Worry About Cavitation?

(Bubble implosion)

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Cavitation

P1
Static
Pressure

Cavitation
P2

Pv

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Valve Cavitation Damage

Pitting

and erosion of
exposed surfaces

Accelerates valve wear

Increases maintenance
and process down-time
Larger

Scale Cavitation:
potential catastrophic
failure of valve body &
pressure vessel walls

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Cavitation

Localized

Erosion
Sounds like rocks
Will attack any
material
Worse with high
pressure

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Why Worry About Cavitation

System
shutdown
Lost
productio
n
Poor
control
High
maintenance

Downstream
pipe erosion
Noise
Pipe
vibration
Trim & body
wear
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Cavitation Management Strategies

Prevention

Control Pressure Recovery by Reducing Velocity

Increase Flow Resistance via Staging

Containment

Control Bubble Collapse Location & Size

Removed From Surfaces
In Low-Impact Regions (e.g. Cage Hole)
Reduce orifice size ( Small hole diameter-Drilled cages)

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Technology Selection

Single

Stage Pressure Letdown

Double Stage Pressure Letdown
Multi-Stage Pressure Letdown

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Energy Management
Step
Letdown

DP = P1 P2

Single

DP

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Energy Management
Multiple

Single

Step
Letdown

Step Letdown

DP
DP

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Single Stage Cavitation

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Multi Stage No Cavitation

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Hydrodynamic Flow Regimes

Subcritical
Static
Cavitating

Pressure
P1

Vapor Pressure

Flashing

Pressure Letdown Path

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Single Stage Cavitation Containment

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Single Stage Cavitation Containment

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What is Flashing?

Pressure

P1

Pv
P2

Inlet Pressure

Vapor Bubble Formation

Outlet Pressure

Vena Contracta

Flow

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What is Flashing?

Pressure

P1

Inlet Pressure

Low Pressure Recovery = High FL

High Pressure Recovery = Low FL

Pv
P2

Vapor Pressure
Outlet Pressure

Vena Contracta

Flow
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Effects of Flashing

Smooth

cuts
Material Loss
Body Damage
Trim Damage
Piping Damage

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Treatment of Flashing Surface

Flashing

cannot be prevented by valve design

Armoring of valve trim and body
Upgrade body to Chrome-Moly or Stainless Steel
Hardening of trim parts or hardfacing
Back pressure devices to increase P2 pressure and postpone
flashing
Expanded outlet valve to slow impact of water droplets
Control the valve and line velocities via selection of valve and
line size
Multistep valves to dissipate initial energy release within the
valve trim

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Erosion

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Wire Drawing

Erosion
Seat

leakage at high
pressure
Cavitation secondary

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CHOKED FLOW
Choked flow :Formation of vapor bubbles in the liquid flow
stream cause a crowding condition at the vena
contracta which tends to limit flow through the
valve.
If valve pressure drop is increased slightly
beyond the point where bubbles begins to form,
a choked flow condition is reached. With
constant upstream pressure, further increase in
pressure drop will not produced increased flow
through the valve.

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Valve Noise
1.Mechanical Vibration
Due to response of internal components within a valve to
turbulent flow through the valve.
Turbulent flow inside the valve may induce vibration against
neighboring surfaces.
2.Aerodynamic Noise
Aerodynamic noise is a direct result of the conversion of the
mechanical energy of the flow into acoustic energy as the
fluid passes through the flow restriction.

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Valve Noise

3.Hydrodynamic Noise
Liquid flow noise, Cavitation noise and flashing noise can be
generated by the flow of a liquid through a valve and piping
system. These constitutes the hydrodynamic noise.
Noise due to Cavitation is the most serious one because it
can be a sign that damage is occurring at some point in the
valve or piping.

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NOISE CONTROL

PATH TREATMENT
INSULATION OF PIPE
HEAVY WALLED PIPE
SILENCER

SOURCE TREATMENT
VALVE CAGE STYLE ( TRIM )
BY INLINE DIFFUSER
BY WHISPER DISK

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NOISE CONTROL - SOURCE TREATMENT

WHISPER - III DESIGN

WHISPER - I DESIGN
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NOISE CONTROL - SOURCE TREATMENT

WHISPERFLO DESIGN BY FISHER

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NOISE CONTROL - SOURCE TREATMENT

WHISPER DISK AND

IN LINE DIFFUSER
DESIGN BY FISHER

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NOISE CONTROL - SOURCE TREATMENT

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CONTROL VALVE GLAND PACKING

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IMPORTANT DESIGN CONSIDRATION

DEAD

BAND:- the range through which an input signal can be

varied, upon reversal of direction, without initiating an observable change

in terms of output.
Main cause of dead band:1)
Friction( for rotary valve- high seat load, for slinding stem valvespacking friction)
2)
Back lash is slack or looseness of mechanical connection
3)
Relay dead zone

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IMPORTANT DESIGN CONSIDRATION

ACTUATOR-POSITIONER DESIGN

VALVE RESPONSE TIME

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Control valve sizing:

Factors to be considered
Flow application data:
Maximum & minimum flow rates, upstream & downstream pressure, Stream
temperature.
Fluid data:
Name & properties of fluid, Phase of fluid ,density of fluid ,viscosity of fluid,
vapor pressure.
Piping influences:
Presence of reducers or other disturbances at valve .
System influences :
Control dynamics, Economic factors, Safety.
Style of valve:
Capacity, Rangeability, Corrosion or erosion, Special requirements.
Sizing:
Manufacturers sizing coefficient.
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SELECTION OF CONTROL VALVES

VALVE SELECTION PROCESS:
Determine
Select

appropriate ANSI pressure class required for valve body and trim.

Calculate

service conditions

preliminary Cv required

Check noise and cavitation levels

Select

trim type

Select

valve body and trim size

Select

trim materials as per application

Actuator
Fire

type, Seat leakage class, Fail safe, Stroke time,

safe, SIL, Hazardous area details as per process requirements.

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CONTROL VALVE DATA SHEET

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INSPECTION AND TESTING

INSPECTION AND TESTING OF CONTROL VALVES:
Material Test certificates of Valve body and components, statutory certificates
from CMRI/ATEX,PESO & BIS for SOV, Positioner, Limit switches etc.
Visual and dimensional check.
Hydro test of valve body
Seat leakage as per FCI 70-2
Valve closing/opening and timing check.
Functional test of Positioner
Accuracy, repeatability and hysteresis of Positioner
Partial stroke /Valve signature test as applicable.
Functional test on accessories like AFR, booster, Air lock relay etc.
Inter-operatabilty and communication check of positioner with Hand held
communicator
Pneumatic test on actuator.
Helium leakage test if specified.

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INSPECTION AND TESTING

SEAT LEAKAGE CHECK

SEAT LEAKAGE PRESSURE

FUNCTIONAL/OPERATION CHECK

CLOSING/OPENING TIMING CHECK

CLOSING/OPENING TIMING CHECK

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INSPECTION AND TESTING

DIMENSION CHECK

DIMENSION CHECK

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INSPECTION AND TESTING

ACTUATOR & TUBING CHECK

HELIUM LEAKAGE TEST

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INSPECTION AND TESTING

Positioner configuration through Hand

held communicator

Valve signature through PST Positioner

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LEARNING FROM INSPECTIONS

a)

Problems related to volume tank:

It is observed that supplier doesnt meet the PR requirements related
to Volume tank, connections and related accessories

Problem: It is observed that drawings which supplier is submitting

shows only schematic diagram of tank, no details Viz. dish end
Type, Foundation, leg arrangements including orientations with
main valve and shell thickness. This issue was observed in IREP
Kochi order, which contributed delays of 20-25 days.

Suggestion: supplier should include all details pertains to volume

bottle as specified above along with valve drawing for EIL review
to avoid last minute conflicts

.
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LEARNING FROM INSPECTIONS

b)

Tubing details along with end connection with tank :

It is observed that supplier is not providing end connection, tubing

arrangements & length details from tank inlet to battery limits and tank
outlet to Air filter regulator to avoid any modification at site.

Suggestion: Above details to be specified in valve drawings for EIL

review.

c)

Tank accessories like gauges and PSV, Connectors etc:

This is observed that supplier is providing unapproved make of

accessories on tank as details of these are not being furnished along
with Tank drawings.

Suggestions: Supplier shall submit the procurement details (vendors

validity) well in advance for review.
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LEARNING FROM INSPECTIONS

d) Regarding

documents validation of special metallurgy and

Volume tank:
Mechanical interface required for review of inspection docs related to
volume tank and special metallurgy viz SS347,SS321,DUPLEX for
valve casting.
Suggestion: Arrangement and submission of above docs well in
advance by supplier prior to final inspection of special metallurgy and
volume tank.

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Thank You

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