Process Control

&
Automation
If you have a smart project, you can say "I'm an engineer“

Lecture 7

Staff boarder
Dr. Mostafa Elsayed Abdelmonem
Process Control & Automation

 Lecture aims:
 Understand the construction of valves
 Identify the valve operations
Introduction to Control Valve
Process control loop

 Representation of a typical process control

 Final control element (FCE) – typically control valve
 Control valve 5

Valves are used to Here is a pneumatic

manipulate gas control valve, using
and liquid flows. air pressure to
manipulate the
valve opening.

[http://en.wikipedia.org/wiki/Control_valves] F. Haugen. Process Control. NMBU. 2017.

Principal design of a pneumatic Air pressure supply Control valve

control valve:
Control air
pressure

Control signal
(from controller) IP-converter
(from current (I)
to pressure (P))
Spring

Indicator displaying
valve opening

Packing box
Plug
Seat Fluid outlet

F. Haugen. Process Control. NMBU. 2017. 6

Fluid inlet
[http://nn.wikipedia.org/wiki/Reguleringsventil + FH]
Role of control valve

Control of pressure at the chamber

Symbol

ACTUATOR

POSITIONER

VALVE
ISA Definition of control valve

Instrument Society of America (ISA) defines the control valve

as a power operated device that modulates the fluid flow rate
in a process control system
Control valve classification
 Parts of a Valve
1. Closure member: part of the valve that closes
flow (disk, ball, gate, etc.).

2. Actuator: means of operating the valve – hand,

gear, chain wheel, motor, solenoid, pressure and
flow of the media, air pressure.
3. End fitting: must be specified when buying the valve - butt weld
end, compression flange, pipe thread, quick disconnect

4. Material: closure member, housing, seat – stainless steel

5. Packing/seals: seals stem, replaced

6. Seat: where the closure members seals against the valve housing
Sliding stem control valve
Major components in SS control valve
Major components in SSV
 Valve body assembly
 Bonnet Pressure Retaining Components
 Bolting
 Seat ring
 Plug
 Stem
 Cage Trim Materials
 Packing
 Seal ring
 Gasket and shim
 Actuator assembly
Major components in SS control valve
Valve Body

 Main fluid boundary and pressure containing component

 Valve body Includes

 Provision for securing internal parts

 End connections that allows installation in the pipeline
 Provision for attaching the bonnet
End connection
 End connection provide the means for installation of control valves in pipelines

 Different types of end connections are

 Screwed end connection

 Welded end connection

 Raised face flange (RF)

 Flat face flange (FF)

 Separable flange

 Ring type joint (RTJ)

 Wafer style
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
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

Butt weld joint

Butt Weld end

Connection
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.
 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
 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
 End connection – Ring type joint (RTJ)
 Well suited for extremely high pressure applications but generally not used at high temperature,
The Ring Type Joint was designed for the Petroleum and Petrochemical industries

 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

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
Valve Types
BallValve
Butterfly Valve
Gate Valve
Globe Valve
Check Valve
 Ball Valve
Sphere with a port in a housing, rotate to expose channel.

 Applications: Flow control, pressure control, shutoff, corrosive

fluids, liquids, gases, high temp.

 Advantages – low pressure drop, low leakage, small, rapid opening

 Disadvantages – seat can wear if used for throttling, quick open

may cause hammer
Ball Valve
 Gate Valve
Sliding disk, perpendicular to flow

Applications: Stop valves, (not throttling), high pressure and temp,

not for slurries, viscous fluids

Advantages – low pressure drop when fully open, tight seal when
closed, free of contamination buildup

Disadvantages – vibration when partially open, slow response and

large actuating force
Gate Valve
 Butterfly Valve
rotating disk on a shaft, in a housing

Low pressure, large diameter lines where leakage is unimportant

Advantages – low pressure drop, small and light weight

Disadvantages – high leakage, high actuation forces so limited to

low pressures
Butterfly Valve
 Check Valves
allows flow in only one direction

Swing valve similar to butterfly except hinged along one

edge rather than rotate about the diameter, used primarily
for check valves.
Check valve
 Globe Valve
three types (globe, angle and Y), disc or plug moved perpendicular to flow
and closes on a ring seat Throttling, general purpose flow control valve

Advantages – faster than gate, seat less wear and tear, high pressure drop
for pressure control

Disadvantage high pressure drop, require considerable power to operate

(gears and levers), heavy
Globe Valve
Valve Symbols
Butterfly Valve

Ball Valve

Gate Valve

Globe Valve
 Role of Positioner

 A device that keeps the valve stem at desired position with

greater accuracy and stability

ACTUATOR

POSITIONER

 Provides feedback to the control system

VALVE

 Reduces dead band and hysteresis in the system

Pneumatic Positioners

 Used in conventional pneumatic plants.

 Input signal  3 – 15 psig

 No advanced diagnostics/performance diagnostics features.

 Mainly used in MRO business now.

 Basic Instrument concept
 Flapper Nozzle:

 Very High sensitivity.

 Zero Order Instrument

 Ps =K * Pb/X
 Operation:

 Nozzle has an internal fixed restriction and a variable

restriction at the end.

 Flapper moves closer then back pressure generated

increases and vice versa.
 Relay Operation.
 Pressure amplification.

 Based on input signal, supply valve opens.

 Exhaust closes.

 Supply pressure flows to the actuator

proportional to the input signal.
3582 Positioner
3582 Positioner

 Includes Flapper-Nozzle assembly.

 Relay used for pressure amplification.

 Beam is balanced between the Input signal and

the travel feedback linkage.

 Direct/Reverse acting.
3582 Positioner
3570/470 Positioner