NIDHIN MANOHAR

The Boss of Control Loop,

Final Control Element

1
CONTROL VALVE
AN OVERVIEW

2
TODAY’S DISCUSSION

CONTENT -
• WHAT IS A CONTROL VALVE ?
• CONTROL VALVE ACTUATOR & ACCESSORIES
•STANDARDS APPLICABLE FOR CONTROL VALVE
•FLASHING
•CAVITATION
•CONTROL VALVE SELECTION & INTERCHANGEABILITY
•VALVE GLAND PACKING & MATERIAL OF CONSTRUCTION
•CONTROL VALVE LEAKAGE CLASS
• CONTROL VALVE CHARACTERISTICS
• ARDUOUS SERVICE VALVE
• NOISE REDUCTIONS PRACTICES
3
WHAT IS A CONTROL VALVE ?

CONTROL VALVE
This is a device used to modulate flow of process fluid in line by
creating a variable pressure drop in the line .

Normally the pressure drop is made with respect to the control signal
received towards flow condition correction required.

4
 WHAT IS VALVE FLOW COEFFICIENT ?

VALVE Cv - No. Of US gallon [ USG = 3.7 Ltrs] of water per minute

passing through the valve in full open condition with 1 PSI pressure
Drop across the valve at 15 deg C temp.
So essentially valve Cv is capacity of valve in terms of water which
helps us to identify suitable size required for any fluid in any pressure /
temp. condition.
VALVE Kv - Quantity of water in M3/Hr. at temperature between 5 to
40C that will flow through the valve at a specified travel with a pressure
drop of 1 Bar.
Kv = 0.856Cv

5
TYPE OF CONTROL VALVE

All Control valve can be divided in two category.

1. Sliding stem ( Globe valve) 2. Rotary shaft ( Quarter turn )

Also valves may be further subdivided as shown below

BY SHAPE BY INTERNAL BY CHAR. BY GUIDING
GLOBE PLUG EQ% TOP
SINGLE SEAT
DOUBLE SEAT
BUTTERFLY CAGE LINEAR CAGE
ANGLE FULL BALL QUICK OPEN TOP & BOTTOM
SLANT SLEEVED PARABOLIC BUSH/BEARING
Y TYPE V BALL 6
VALVE ACTUATOR

Actuator - Mechanism which

operates the valve by receiving the
control signal.
Type of Actuator
Pneumatic - Spring Diaphragm
Piston Cylinder
Electrical - Not discussed
Hydraulic- Not discussed

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VALVE ACTUATOR

8
VALVE ACTUATOR

9
VALVE ACCESSORIES

VALVE POSITIONERS
PNEUMATIC
ELECTRONEUMATIC
SMART DIGITAL
PROXIMITY SWITCHES
INDUCTIVE TYPE
PNEUMATIC CAM OPERATED
SOLENOID VALVES
LATCHING/ NON-LATCHING
WITH MANUAL OVERRIDE
SIGNAL BOOSTERS
PRESSURE
VOLUME
SIGNAL INVERTERS
HANDWHEEL
AIR VOLUME TANK

10
CONTROL VALVE STANDARDS

ANSI :- AMERICAN NATIONAL STANDARDS INSTITUTE

B16.34 :- STEEL VALVES
• DEFINES CRITERIA FOR VALVE WALL THICKNESS REQUIREMENTS
• DEFINES PRESSURE / TEMPERATURE RATINGS
• DEFINE HYDRO-TEST REQUIREMENTS
Example :-
A351 CF8M ( Material :- 316SST; Temp range :- -425 °F to 1500 °F)
A216 WCB ( Material :- Carbon Steel; Temp range:- -20 °F to 1000 °F )

B16.37 :- HYDROSTATIC TEST PROCEDURE

• DEFINES REQUIREMENT FOR HYDRO-TEST = 1.5 X MWP
MWP = MAXIMUM WORKING PRESSURE

B16.104 :- CONTROL VALVE SEAT LEAKAGE CLASSIFICATION

• ESTABLISHES TEST PROCEDURES AND SEAT LEAKAGE CLASSES

API :- AMERICAN PETROLEUM INSTITUTE

SPEC 6B :- DEFINES PIPELINE VALVE
SPEC 600 :- STEEL GAGE VALVES, FLANGED BUTT WELDING ENDS

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CONTROL VALVE STANDARDS

NACE :- NATIONAL ASSOCIATION OF CORROSION ENGINEERS

NACE MR-01-75
• DEFINES SULFIDE STRESS CRACKING RESISTANCE MATERIAL
• MATERIAL COMPLY TO NACE STANDARD ARE
CARBON STEEL WITH HEAT TREATMENT
SST 302,304,316,17-4PH
ALLOY STEEL MONEY, HASTELLOY C
• MATERIAL NOT SUITABLE FOR NACE ENVIRONMENT IS
CAST IRON

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CONTROL VALVE STANDARDS
ISA :- INSTRUMENT SOCIETY OF AMERICA
• DEFINES STANDARDS FOR CONTROL INDUSTRY
Example :-
VALVE SIZING EQUATIONS.
NOISE PREDICTION TECHNIQUE
CONTROL SIGNAL 3 - 15 PSIG, 6 - 30 PSIG

OSHA :- OCCUPATIONAL SAFETY AND HEALTH ACT

DEFINES CRITERIA FOR PERMISSIBLE DURATION FOR EXPOSURE OF NOISE LEVEL

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SHELL REFERENCES

Control Valves –Selection , Sizing and Specification

• DEP 32.36.01.17- Gen July 1987 &

• Basic Process control & Instrumentation Shell
M114-1999
• Shell Best Practice –[Ref Process Measurement
and Control Devices –Shell Canada Ltd
Standard 16-1.2]

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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

ANSI/FCI 70-2 Maximum Leakage Test Medium Pressure and temperature

Class II 0.5% valve capacity at full travel Service DP or 50 PSID
Class III 0.1% valve capacity at full travel Water / Air whichever is lower at 10 to
Class IV 0.01% valve capacity at full travel 52deg C
Class V 0.0005ml/min/psid/in. port dia Water Service DP at 10 to 52deg C
Bubbles per
Port dia. mL per Min.
Min.
1 1 0.15
1 - 1/2 2 0.30 Service DP or 50 PSID
Class VI 2 3 0.45 Air whichever is lower at 10 to
2 - 1/2 4 0.60 52deg C
3 6 0.90
4 11 1.70
6 27 4.00
8 45 6.75

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 VALVE CHARACTERISTICS

Equal % - Rate of change of flow due to change of valve

travel is proportional to earlier
flow.

Linear - Rate of change of flow is same to rate of

change of valve travel

Quick Open - Full capacity attaining without change of

travel after initial opening

On/Off - Used mainly as Isolation valves (Pump

suction and ESD valves)
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 TRIM AND CAGE DESIGN

1. CHARACTERISING FLOW
• Linear Cage
• Quick Opening Cage
• Equal Percentage Cage
• Modified Equal percentage flow

2. NOISE ABATEMENT

3. ANTI CAVITATION

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CHARACTERIZING FLOW BY CAGE TYPE

19
CHARACTERIZING FLOW
100

Quick
80
% Opening

60
Design Cv
Cv

40

20

0
0 20 40 60 80 100
% Valve Travel
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VALVE SELECTION PROCESS FOLLOWED
IN RELIANCE

• If valve sizing does not give warning of cavitation, flashing or Noise level ( >85dBA) then
select standard trim valve.
• If valve sizing gives warning of cavitation, flashing or Noise level ( >85dBA) then select
arduous service trim valve.
Example:- For cavitation select CAVITROL III stage 1 to 5 valve or CAVITROL 4 valve.
For noise select WHISPER I ,III or WHISPERFLO valve trim.
• Select the suitable Approved vendor suiting the product .
Example:- ABB - Introl design or CCI - DRAG design.
• In case of very high DP ( DP*100/P1 > 50%) or Noise select ABB or CCI valves.
Example:- Compressor Anti - surge control valves - CCI- DRAG design.

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VALVE SELECTION PROCESS
Standard Materials :
Carbon steel WCB Is it No
Carbon steel NACE standaard
Stainless steel 316 or 316L material
Yes
Standard Ratings :
ANSI rating class 150 Is it standard No

ANSI rating class 300 flange rating

ANSI rating class 600
Yes

Special valve design

and application
ref DEP 32.36.01.17
Is
Standard Temp. Rangge
temperature No
0 deg. C withing
+ 420 deg. C standard
Yes
range

Severe Service :
Choke Flow
Cavitation
Noise above 85dbA
Oxygen service Is it sever Yes

Low temperature service service

HF service
No
Ethylene oxide service
Standard valve design
Vacuum service
and application.
HP steam service Ref DEP 32.36.01.17
All Section except 6
Hydrogen service
and 7
Chlorine service 22
POPULATION OF CONTROL VALVES AT
RELIANCE JAMNAGAR.
• Based on above criteria RIL complex has following Installed quantity of
valve
• Fisher direct supply ( Through Bechtel ) :1800+ valves.
• Fisher package supply valves :800+
•Masoneilan package supply : 180 +
• ABB UK direct supply :150+
• CCI USA direct supply :40+
• Fisher Gulde package supply : 190 +
• Linde Mepag package supply : 120 +
•Copes Vulcan package supply : 50 +
•Keystone Biffi direct supply : 300 +
•Neles Jamesbury direct supply : 63023+
•Rotork MOVs direct supply : 2100 +
VALVE INTERCHANGEABILITY
• Body pressure rating and certification ( e.g. IBR )
• End connection ( Ex:- Screwed or welded flange connection )
• Valve Size and type.
• Trim Size - Cv
• Leakage classification
• Body and trim material and certification ( e.g. NACE )
• Plug and cage characteristics.
• Actuator bench setting / spring range.
• Actuator action ( AFC/ AFO )
• Process temperature ( For gland packing and body - trim material )

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Flow Path through a Control Valve - Analogy
Minimum
Geometrical
Flow Area

Streamlines Contract as Vena Contracta

Flow Approaches Restriction (Minimum Flow Area)

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Variation in Pressure and Velocity

P1

Pressure
Velocity DP
Variation
Variation

P2

Valve Trim Valve

Inlet Trim Exit Vena Outlet
Inlet Contracta
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Pressure Recovery

DP

Low
Recovery

High
Recovery

Valve Trim Valve

Inlet Trim Exit Vena Outlet
Inlet Contracta
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FLASHING

Flashing :
The formation of vapor bubbles in liquid flow streams at vena contracta.

As liquid passes through a restriction (vena contracta) in a control valve the liquid velocity
increases and liquid pressure decreases. And if the pressure at this point falls to or below
the vapor pressure of the liquid, vapor bubbles form in the flow stream. Flashing results if
this pressure remains below vapor pressure of liquid.

When a liquid flashes into vapor, there is a large increase in volume. Due to increase in
volume velocity will increase and hence high velocity will erode the surface.

Flashing damages can be identified by smooth polished appearance of eroded surface.

Flashing damages is usually at or near seat line of the valve plug and seat ring.

Vapor pressure :- The pressure at which liquid begins to vaporize.

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FLASHING DAMAGE ( Tag no. 241FV040 )

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FLASHING DAMAGE ( Tag no. 241FV040 )

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CAVITATION

Cavitation : The formation and subsequent collapse of vapor bubbles in liquid flow
streams.
As liquid passes through a restriction in a control valve the liquid velocity increases, while
the liquid pressure decreases. The pressure reaches a minimum at a point called the vena
contracta, and if the pressure at this point falls to or below the vapor pressure of the liquid,
vapor bubbles form in the flow stream.

Downstream of the vena contracta, flow area increases, velocity de-creases, and pressure
increases.

If this recovered pressure is sufficient to raise the pressure above the liquid vapor pressure,
the vapor bubbles will collapse. The collapsing bubbles generate significant noise and
vibration, and can mechanically attack pipe walls and valve components.

Cavitation damages can be identified by rough and pitted surface. Cavitation damage may
extend to the downstream pipeline if that is where the pressure recovery occurs.
Phenomenon of Cavitation is experienced in CV and PUMPS
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CAVITATION

P1

DP

P2

PV
PVC’

Valve Trim Valve

Inlet Trim Exit Vena Outlet
Inlet Contracta
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CAVITATION DAMAGE

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CAVITATION CONTROLS

•SYSTEM DESIGN
1. LOCATION OF VALVE
2. CASCADING
•MATERIAL SELECTION
HARDEN MATERIAL,
LIKE 17-4 pH, 440C, 420SST HT
AND 316/COLMONOY 6 / ALLOY 6

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CAVITATION CONTROLS

• ANTI - CAVITATION PRODUCTS

• CCI DRAG DESIGN, UP TO 380 BAR PRESS. DROP.

• FISHER CAVITROL - III DESIGN

CAVITROL - III WITH 1 STAGE- UP TO 99 BAR.
CAVITROL - III 2-3 STAGES- 99 TO 207 BAR.
CAVITROL -4 , ABOVE 200 BAR, SIZE LIMIT 2” TO 6”.

• ABB INTROL DESIGN

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CAVITATION CONTROLS :- FISHER
CAVITROL DESIGN

CAVITROL - III CAVITROL - III

STAGE - 2 STAGE - 3

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CAVITATION CONTROLS :- FISHER
CAVITROL DESIGN

CAVITROL - 4

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CAVITATION CONTROLS :- ABB INTROL
DESIGN

INTROL CAGE

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CAVITATION CONTROLS :- CCI DRAG
DESIGN

CCI DRAG CAGE

39
CAVITATION CONTROLS :- CCI DRAG
DESIGN

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CAVITATION CONTROLS :- CCI DRAG
DESIGN

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CHOKED FLOW

Choked flow :-
Formation of vapour 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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NOISE FUNDAMENTALS

Noise :- A random mixture of sound pressure waves of various amplitudes and frequency. Which
people do not like to hear.
Sound Wave :- A pressure wave with a fixed frequency and amplitude traveling through a medium.
Unit of Noise :- dBA ( Decibels )= 20 Log( Existing sound pressure level / 0.0002 microbars )
Source of valve noise:
• Mechanical Noise :- It produces high mechanical stress - fatigue failure of vibrating part.
Mechanical noise can be solved by improved design to suppress vibration
by good guiding and rugged construction.
• Vibration of valve components :- This is due to lateral movement of valve plug relative
to guide surfaces. The sound level produce normally will have frequency less then
1500Hz and is describe as metallic rattling.
• Fluid impingement upon the movable of flexible part ( Metallic chattering )
• Components resonates at its own natural frequency ( single tone 3KHz to 7KHz)

• Hydrodynamic Noise :- It is due to cavitation. It is because of implosion of vapor bubbles and

is relatively low.
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NOISE FUNDAMENTALS

Aerodynamic Noise :-

Highest energy component at same frequency where human ear is most sensitive. Large
amount of energy converted to aerodynamic noise.

• High intensity noise resulting due to turbulent flow of gas, are due to high relative
velocity.
This can be classified as non-periodic or random noise with occurring frequency between
1 KHz to 8 KHz.
• Valve pressure drop ( Main source ),
• Obstruction in flow path,
• Valve style , having more flow directional changes,
• Degree of turbulence varies with valve style1,
• Valve size.

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PERMISSIBLE EXPOSURE DURATIONS NOISE
LEVEL
OSHA :- OCCUPATIONAL SAFETY AND HEALTH ACT
DEFINES CRITERIA FOR PERMISSIBLE EXPOSURE DURATIONS NOISE LEVEL
IN JAMNAGAR COMPLEX MAX. 85 dBA IS CONSIDERED AS A VALVE SELECTION
CRITERIA.
DURATIO N IN HO URS PER DAY SO UND LEVEL IN DBA
8 90
6 92
4 95
3 97
2 100
1-1/2 102
1 105
1/2 110
1/4 O R LESS 115
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NOISE CONTROL

• PATH TREATMENT
• INSULATION OF PIPE
• HEAVY WALLED PIPE
• SILENCER
• SOURCE TREATMENT
• VALVE CAGE STYLE ( TRIM )
• WHISPER - I ( DP/P1 <= 0.65 ), Noise reduction up to 18 dBA.
• WHISPER - III ( 0.6 <= DP/P1 <= 0.99 ), Noise reduction up to 30 dBA.
• WHISPERFLO (NEW DESIGN), Noise reduction up to 10 dBA.
• BY INLINE DIFFUSER
• BY WHISPER DISK

46
NOISE CONTROL - SOURCE TREATMENT

WHISPER - III DESIGN

WHISPER - I DESIGN 47
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 CALCULATION

SPL = SPLDP + DSPLCG + DSPLDP/P1 + DSPLK + DSPLP2

SPL = OVERALL NOISE LEVEL IN DECIBLE ( 1 METER DOWNSTREAM OF VALVE OUTLET
AND 1METER FROM THE PIPE SURFACE )
SPLDP = FUNCTION OF PRESSURE DROP ACROSS THE VALVE ( MAJOR COMPONENT )
DSPLCG = GAS SIZING COEFFICIENT ( MAJOR COMPONENT )
DSPLDP/P1 = RATIO OF PRESSURE DIFFERENTIAL TO INLET PRESSURE
DSPLK = CORRECTION IN DBA FOR PIPE SIZE AND SCHEDULE
DSPLP2 = DOWNSTREAM PRESSURE

SIMPLIFIED EQUATION ( WITHOUT MUCH LOSS OF ACCURACY ) :

SPL = SPLDP + DSPLCG

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CONTROL VALVE GLAND PACKING

51
CONTROL VALVE GLAND PACKING

Suitablity
Temp. for Oxygen Stem Special
Common use Packing material Description
Range /Oxidizing friction consideration
Service
Split rings of braided
PTFE impregented
-73 to 232C Non-Radioactive Yes composition impregented with Low -
composition
PTFE
All chemicals ( Except
Required 2 to 4
Molten alkali) Non No single PTFE V - Ring Solid rings of molded PTFE Low
micro inch RMS
-40 to 232C radioactive
valve plug stem
Vacuum Pressure /
No Double PTFE V - Ring Solid rings of molded PTFE Low finish
Vacuum
Split rings of braided,
preshrunk PTFE yarn
impregented with PTFE;
Vacuum, All chemicals available with copper rings at
-84 to 232C Yes Chesterton 324 Low -
( Except molten alkali ) top and bottom of packing
box to meet UOP
specification 6-14-0 for acid
service.
Low chloride
Water, Stem Petroleum Ribbon style graphite rings content ( less then
products, Radiactive Yes but upto Graphite/ and rings of braided graphite 100ppm) chrome
-18 to 538C High
and Non-radiactive 371C Ribbon/Filament fibers with sacrificial zinc plated stem not
nuclear washer necessary for high
temperature service

Solid rings of ribbon-style

High temperature Ribbon - Style
371 to 649C Yes graphite with sacrificial zinc High -
oxidizing service graphite
washers

52
 VALVE MATERIAL

Essentially material for the valve is valve assembly MOC. Standard

material commonly used can be listed as below -
Valve Body & Bonnet - As per Process
Internals - As per Process . Commonly SS316 with or w/o
stellite.
Valve Gasket - Graphite, Metallic SS 316 or SS 316L
Valve Packing - Commonly Teflon Or Graphite
Fasteners - B7 or B8M
Actuator Yoke - Cast Iron
Actuator Spring - Spring Steel
Actuator Diaphragm - Nitrile Rubber with fabric reinforcement
Accessories - Commonly Aluminum.

53
 TECHNOLOGY

With the advent of new technology Control Valve has

undergone rapid change in terms of change in Internals,
Capacity Increase, Guiding, Leakage Class Improvement,
Treatment of Noise And Cavitation And Finally
DIGITAL.

About 30 years back control valves were only available

with top guided or top & bottom guided design with
asbestos packing and practically no solution available
for Hi Pressure drop application leading to Noise for Gas
service Or Cavitation for Liquid Service.

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 TECHNOLOGY

Now a days we are also having control valve with digital technology,
where valve positioner is digital in nature and able to provide PID
function at the valve itself. Digital positioner can provide the following
apart from acting as interface between controller and valve actuator -
1. Provide HART feedback.
2. Can couple with Foundation Fieldbus.
3. Can provide valve diagnostics.
4. Helps in Asset Management.
5. Provide lock, soft alarms and data logging facilities.
6. Can achieve split action, remote calibration etc.

55
Trouble Shooting in Control Valves.

TROUBLE SHOOTING

MALFUNCTION

ACTION LEAKAGE OTHERS

INSTABILITY CYCLIC MOTION VIBRATION (NOISE) DULL RESPONSE NOT WORKING

HUNTING HUNTING At any vlv At specific

(At any vlv opening) (Near to vlv close posn) opening vlv opening

High Stem Friction Oversizing Flow to Close Poor Increse Resonance of Resonance
flow direction Piping Support Vibration Noise
of vlv plug

Other Find
To Check Reduce dP Change source Increase Change
Gland Packing Flow dir. pipe support plug
profile
Plug guide Replace
Increase Use Smaller wear & tear with new Throtle pump Change
Actuator Cv valve discharge Cv value
valve

Check Vlv
Guiding

56
Trouble Shooting in Control Valves.

Trouble Shooting

MALFUNCTION

ACTION LEAKAGE OTHERS

CYCLIC MOTION DULL RESPONSE NOT WORKING

Travel Not Travel Not

smooth smooth
(In both dir) (In one dir)

Leak in Leak from

Slurry/sludge Actuator Change Gland pkg Change Actuator Act. stem
in vlv guide piston ring Piston ring hardened gland pkg diaph. seal
wear & tear

Change Change
Dissemble & diaph. stem seal
Clean

Use dust
Enlarge seal bellow
guide ring
bleeder hole

Provide
flashing port

Use jacketed
vlv body

Use rotary
or angle type
valve

57
Trouble Shooting in Control Valves.

Trouble Shooting

MALFUNCTION

ACTION LEAKAGE OTHERS

CYCLIC MOTION DULL RESPONSE NOT WORKING

No signal & No signal pr. No sup. pr. Posn O/P Nil Actuator not
supply pr. sup pr. avl Signal pr. avl working with
air sup.

Trouble in Trouble in Check AFR Clean Trouble in Check Stem/guide Disassemble

air source controller Controller contamination Filter posn pilot galling / jamming & check
relay

Trouble in Control sig Check Pn tubing Check Tubing Act diaph Change Foreign particle Disassemble
electric source leakage air tubing Leakage (mainly air air leak parts in vlv port & check
conn.)

Leakage from Act diaph Change parts Trouble with Check Stem Bend Change
tubing air leak AFR AFR parts

Check comp. Positioner Change bellow Trouble in Check

elec source & air leak or diaph Actuator Act Stroke
Main air tubing

58
Trouble Shooting in Control Valves.

MALFUNCTION

ACTION LEAKAGE OTHERS

CYCLIC MOTION

Drift of Hunting of Hunting of

air sup pr. Sig air pr. Vlv stem

Too much air Trouble in Control loop Trouble in Positioner Shift in plug
consumption AFR Resistance Controller loop hunting reaction force
in other line

Enlarge Check AFR Insert vol tank Check Check posn Decrease dP
compressor & restriction to Controller parts friction
capacity air signal loop

Exclusive Check posn Higher size

compressor pilot relay Actuator

59
Trouble Shooting in Control Valves.

MALFUNCTION

LEAKAGE OTHERS

Seat Leak Gland Leak Rangeability narrowed

because of
control position
changed

Valve Closed Valve not Insufficient Corrosion / erosion

able to close pkg nut tight of plug or S. ring

Corrosion & erosion Corrosion & erosion Leakage Too high dP Galling on Tighten Change seat ring
of vlv seating of seat ring thread thro' inner guide or port pkg. nut or plug
surface or gasket vlv body wall

Pkg Lub
Remachine & Lap Change seat Tack weld Reduce dP Check for missing
seat surface & seat gasket defect area Foreign parts

Change Check Change vlv Increase Remachine

seat & plug seat design body Actuator size galling portion Provide
lub or chg pkg.

Wear & tear

of pkg

Change
pkg

Damage of stem
surface

Change parts
or remachine

Use dust seal

bellows

Corrosion/erosion
of seat gasket
surface

60 Examine part MOC

Change gasket
THANK YOU
61