FUNDAMENTALS OF

CONTROL VALVES
 CONTROL VALVE
■ A CONTROL VALVE IS A FINAL
CONTROL ELEMENT AND A POWER
OPERATED DEVICE WHICH
MODIFIES THE FLOW RATE
IN A PROCESS CONTROL SYSTEM.
ROLE OF A CONTROL VALVE

It is used for
■ The correct distribution and control of

■ Flowing fluid or gases

■ Reduction of Pressure

■ As a variable orifice

■ As a throttling or modulating equipment

CONTROL VALVE PARTS

1. BODY
2. VALVE
3. ACTUATOR
 BODY
■ The body is the pressure carrying part and it
meets all their applicable pressure,
temperature and corrosion requirements.

THE BODY PROVIDES

■ THE PIPING CONNECTING ENDS

■ FLUID FLOW PASSAGE WAY, AND

SUPPORT THE SEATING SURFACE
■ THE VALVE CLOSURE MEMBER
BODY- INTERNAL PARTS

GLAND
BODY FLANGE
PACKING
STEM WITH
PLUG

INLET OUTLET
SEAT
 TRIM
■ The trim of the valve consists of all the
parts which will be wetted other than the
body and the bonnet
■ Trim is the heart of the valve with a
primary function to proportion the valve
orifice in such a manner that a
prescribed relationship exists between
flow capacity and valve plug lift
■ The secondary function may be shut off
tightly.
■ The trim includes Seat, Plug, Stem,
Gland Follower, Gland Nut, Plug, Guide
Bushings and Cage
■ Stuffing box components considered as
trim are the packing, follower, Spring,
Lantern Ring, and Packing Retaining
Ring.
■ Secondary trim parts are stem to plug
attachments , seat retaining ring, seat
to body seals and spacers.
 YOKE

. ■ A STRUCTURE BY WHICH THE

DIAPHRAGM ASSEMBLY IS SUPPORTED
RIGIDLY ON THE BONNET ASSEMBLY
 YOKE
ACTUATOR BASE

SPRING
ADJUSTMENT
SPRING BASE
NUT
STEM COUPLING POINTER
TRAVEL SCALE

BONNET BASE
ACTUATOR
 ACTUATOR
■ UTILISES AIR PRESSURE / ELECTRIC POWER
.
HYDRAULIC PRESSURE
■ TO ACT ON A DIAPHRAGM / PISTON AND
DEVELOP A FORCE TO MOVE THE
ACTUATOR STEM
 ACTUTATOR
CLASSIFICATION
■ PNUEMATICALLY OPERATED DIAPHARGM
• ACTUATOR
■ PNUEMATICALLY OPERATED CYLINDER
ACTUATOR
■ MOTOR OPERATED PISTON ACTUATOR
HYDRAULIC OPERATED PISTON
ACTUATOR
 ACTUATOR PARTS
VENT
DIAPHRAGM
DIAPHRAGM
PLATE
CASINGS
DIAPHRAGM
ACTUATOR
INPUT SIGNAL
SPRING
ACTUATOR STEM
SPRING SEAT SPRING ADJUSTER
YOKE
STEM CONNECTOR
INDICATOR
SCALE
GLAND STUDS
LOCK NUT

STUFFING BOX BONET FLANGE

 •GLOBE

•GLOBE •ANGLE

•THREE-WAY
•LINEAR •GATE

•MOTION •DIAPHRAGM

•PINCH OR CLAMP
•VALVE
•SEGMENTED
BALL
•BALL

•FULL
•ROTARY
BALL
•BUTTER FLY
•MOTION
•CYLIDRICAL

•PLUG •TAPERED

•ECCENTRIC
SPHERE
 T y p e s o f V a v le s

R o t a r y M o t io n

B a ll B u t t e r f ly P lu g

L in e a r M o t io n

G lo b e G a te D ia p h r a g m P in c h o r C la m p

G lo b e A n g le T h re e W a y
IT IS MOSTLY COMMONLY USED ONE.
IT IS A VALVE WITH A LINEAR CLOSURE
MEMBER
MOST COMMON TYPE CONTROL VALVE

CLASSIFIED AS
SINGLE SEATED AND
DOUBLE SEATED
SINGLE SEATED CONFORMS TIGHT SHUT OFF.

DOUBLE SEATED VALVE IS HAVING HIGH

RESISTANCE TO VIBRATION AND
ABRASION.
IT HAVE THE ADVANTAGE OF EASY
TRIM REMOVAL .

IT IS TOP ENTRY VALVE WITH

UNBALANCED, SINGLE-SEATED TRIM.

THE INNER VALVE PARTS CAN EASILY

BE REMOVED AFTER REMOVING THE
BONNET , BECAUSE ABSENCE OF
INTERNAL THREADS.
•

■ ANGLE VALVES ARE SUITABLE FOR SLURRY FLUID ,

ADHESIVE FLUID AND HIGH VISCOSITY LIQUIDS.

■ SUITABLE FOR HIGH PRESSURE APPLICATION.

■ HAS STRONG RESISTANCE TO VIBRATION AND WEAR

•
■ IT IS SIMPLY DESIGN

EXTENSION OF DOUBLE

SEATED GLOBE VALVE.

■ DIVIDES FLOW IN TWO

DIRECTIONS

■ CONVERGES TWO

STREAMS OF FLOW TO

ONE
APPLICABLE WHERE STRAIGHT THROUGH FLOW
PATH , TIGHT SHUT OFF AND EASE OF OPERATION
ARE REQUIRED.

MOST SUITABLE FOR HANDLING SLURRIES AS IT

MINIMISES THE TENDENCY OF THE FLUIDS TO EITHER
SETTLE OR STAIN .

SUITABLE FOR HIGH FLOW CAPACITY..

❇ IT OFFERS THE ADVANTAGES OF SIMPLICITY, LOW COST, LIGHT
WEIGHT,AND SPACE SAVING.

❇   
    
     .

❇ VALVE IS SUITABLE FOR LOW PRESSURE DROP APPLICATIONS

❇ ACTUATOR TORQUE REQUIRED IS LOWEST AS COMPARED TO

OTHER VALVES .

❇ IT HAS MAXIMUM FLOW CAPACITY .

❇ INSTALLATION AND HANDLING IS EASY .

•The most common type of rotary valve used for
control is the BUTTERFLY valve.
•The typical application range is in sizes from 2”
through 36” or larger, for low or moderate
pressures,or on unusual applications involving large
flows at high static pressures ,but with limited
pressure drop.
 IT IS THE RELATION BETWEEN THE FLOW RATE THROUGH THE
CONTROL VALVE AND PLUG TRAVEL , WHEN A CONSTANT PRESSURE
DIFFERENTIAL IS MAINTAINED ACROSS THE VALVE
THIS IS ACHIEVED BY VARYING THE FLUID FLOW AREA WITH
RESPECT TO THE SHAPE OF THE PLUG.

THE DESIGN OF A CONTROL VALVE TRIM IS BASED ON THE

FLOW CHARACTERISTICS .
DIFFERENT CHARACTERISTICS WHICH ARE COMMONLY SELECTED TWO
TYPES
1. TWO POSITION (ON-OFF)CONTROL
2. THROTTLING CONTROL
FLOW CHARACTERISTICS DECIDED BY SHAPE OF PLUG OR CAGE
SLOTS.
•THE PLUG IS THE MOVING COMPONENT OF THE VALVE WHICH

THROTTLES FLOW BY POSITIONING ITSELF WITHIN THE SEAT

ORFICE AND SHUTS OFF FLOW BY CONTACTING THE SEAT.

• THE PLUG IS MOVED AGAINST DYNAMIC FLUID FLOW

FORCES BY STEM FORCE TRANSMITTED FROM THE ACTUATOR.

• THE PLUGS (OR CAGE SLOTS) ARE SHAPED TO THROTTLE

FLOW WITH GIVEN CHARACTERSTICS SUCH AS

•QUICK OPENING,

• LINEAR,

•PARABOLIC OR EQUAL PERCENTAGE .

THREE TYPES OF VALVE CHARACTERESTICS ARE
•QUICK OPENING :
This type of characteristics provides maximum change in
flow rate at lower valve travels, as the plug bottom is flat
with a fairly linear relationship , opening with a small signal
will give the maximum flow rate
Additional increase in valve travel gives sharply reduced
changes in flow rate .
•The common application of the valve is ON -OFF
•LINEAR CHARACTERSTICS:
This type of valve provides change in flow rate which is
linear with the valve lift.
That is this proportional relationship produces a
characteristics with constant slope so that with constant
pressure drop , the valve gain is the same at all flow
rates.
Q = KX
•EQUAL PERCENTAGE :( =% )
Equal increments of valve travel produce flow changes
which are equal percentage of existing flow .
The change in flow rate is always proportional to the
flow rate that exits just before the change in valve
position is made .
Q = Q0 emx
Q0 = minimum controllable flow rate .
m = ln R/T = constant for a particular valve
R= rangeability , T= max. valve lift
Equal Q = Flow QO = QM = X = Valve m = ln R/T mX R/T R=QM / T=1
Percent = ( Rate Min Max Travel QO
Present value Flow Flow
- Previous
value) /
Previous
value.
2.96 2 100 0.1 3.91 0.39 50 50 1
0.48 4.37 2 100 0.2 3.91 0.78 50 50 1
0.48 6.47 2 100 0.3 3.91 1.17 50 50 1
0.48 9.56 2 100 0.4 3.91 1.56 50 50 1
0.48 14.14 2 100 0.5 3.91 1.96 50 50 1
0.48 20.91 2 100 0.6 3.91 2.35 50 50 1
0.48 30.92 2 100 0.7 3.91 2.74 50 50 1
0.48 45.73 2 100 0.8 3.91 3.13 50 50 1
0.48 67.62 2 100 0.9 3.91 3.52 50 50 1
0.48 100.00 2 100 1.0 3.91 3.91 50 50 1
 •Linear

•Equal %

LIFT(%) LINEAR EQUAL % Q.O

10 10 2.96 07
20 20 4.37 24
30 30 6.47 45
40 40 9.56 68
50 50 14.14 83
60 60 20.91 92
70 70 30.92 95
80 80 45.73 98
90 90 67.62 100
100 100 100 100
 •100

•90

•80

•70

F •60

L
O •50

W •40

•30

•20

•10

•0 •10 •20 •30 •40 •50 •60 •70 •80 •90 •100
•% of valve opening
•It is the number of US gallons per minute of water at 60
degree F that will pass through flow restriction at
maximum opening maintaining a pressure drop of 1 psi.
BASIC FLOW RATE FORMULA FOR LIQUIDS IS:
Q = K* A* SQRT {(P1-P2)/G}
Q=Flow rate in gpm or Kg/hr
p1=Upstream pressure in psig or Kg/cm2
p2=Downstream pressure in psig or Kg/cm2
G=Specific gravity at referred temperature
K= DISCHARGE COEFFICIENT, A = AREA
IF G =1 AND P1-P2 = 1, THEN Q = K*A
AS PER THE ABOVE DEFINITION,
Cv = K*A
NOW Q = Cv * SQRT {(P1-P2)/G}

WHICH IS THE RELAVENT FORMULA OF FLOW

COEFFICIENT OF CONTROL VALVE IN CASE OF
LIQUIDS .

THE SAME PROCEDURE WILL BE ADOPTED IN CASE

OF GAS FLOW , STEAM FLOW ETC. WITH SUITABLE
MODIFICATION OF WORKING FORMULA.
•It is effectively an index of pressure recovery in a control valve.
•i.e. High Cf values indicate low pressure recovery where a low
Cf value indication of high pressure recovery .
•when fluid flows through the valve orifice , there is a marked
increase in velocity . This velocity increase is accompanied by
proportional decrease in pressure . Velocity reaches maximum
and pressure a minimum at the smallest cross sectional flow area
downstream of the orifice and that particular point is called
vena contracta.
 •P2
•ORIFICEPLATE

•VENA CONTRACTA

•--------------------------------------------------------------------------------------------------

•VENACONTRACTA
•VELOCITY
•PRESSURE

•PV
•P1
•Control valves give problems mainly in three areas
•1. Cavitation with associate noise and vibration
•2. Flashing
•3. Leakage of fluid around valve stem
•Control valve selection is in step wise
•step 1 : calculate CV
•1.select valve type
•step 2 : select valve size , trim size and characteristics.
•Step 3 : select end connections
•1. End connection type
•2. End connection rating
•Step 4 : select seat leakage
•that is class1/2/3/4/5.
•Step5: select actuator type and size
•step 6: select valve materials
•1. Valve body material
•2.trim material
•3 seat construction as dictated by seat leakage
•4. Guided bushing
•5.soft seat materials for class vi leakage
•Step 7 : select packing material and bonnet type
•1.packing material a)standard Teflon asbestos
•b)Teflon v- ring c)Grafoil
•2. bonnet type
•standard / extended / bellows seal
extension
•step8: select valve accessories
•1.positioner
•2.sov / volume booster / air set / lock up
valve / volume tank / limit switch / travel
stop ………..etc
•IN GENERAL, ALL MANUFACTURERS HAVE THEIR
OWN DESIGN DATA SHEETS, CONSIDERING THE
CRITICAL FLOW , CAVITATION , FLASHING AND
VALVE NOISE OF THE GIVEN PROCESS CONDITION

•WHEN THE CALCULATED Cv VALUE IS KNOWN,

SELECTION AND SIZING OF CONTROL VALVE IS
EASY.
•AIR FILTER REGULATOR
•VALVE POSITIONER
•VOLUME BOOSTER
•QUICK EXHAUST
•AIR LOCK RELAY
•LIMIT SWITCHES
•SOLENOID VALVE
•POSITION TRANSMITTERS
 •POSITIONER :

•The main function of positioner is to ensure that the control

•valve position is always proportional to the value of controller
•output signal regardless of packing box friction,actuator hysteresis
•the unbalanced forces of the plug.
USAGE OF VALVE POSITIONER:

• SMOOTH CONTROL

• CHANGING OF OPERATION MODE

• ACHIEVING SPLIT RANGE

• REDUCING TIME LAG

• CHANGING VALVE CHARACTERSTICS

•ACTION CAN BE REVERSED BY CHANGING THE PILOT.

 SPRING
BELLOWS DEFLECTION

VALVE
STROKE
NOZZLE
S
O W
L
BEL EXHAUST
RELAY
VALVE

RESTRICTION
I/P SIGNAL

C.V.STEM
 TO BELLOWS
FROM NOZZLE
CLASS I NOT SPECIFIED
CLASS II 0.5% RATED VALVE CAPACITY

CLASS III 0.1 % RATED VALVE CAPACITY

CLASS IV 0.01% RATED VALVE CAPACITY

5*10-4ml per min. OF WATER PER

CLASS V INCH OF ORIFICE DIAMETER PER
PSI DIFFERENTIAL

LEAKAGE EXCPRESSED IN ML PER

CLASS VI
MINUTE VERSUS PORT DIAMETER
 1
2 2

5
AVOID
AVOID 5

4 4
3