STEP 1.

DETERMINE THE REQUIRED CV CONTROL VALVE FLOW COEFFICIENT (Cv)

Cv is the number of U.S. gallons per minute of water which will pass through

a given flow restriction with a pressure drop of 1 psi.

Eg. : A control valve which has a Cv of 12 has an effective port area in the full

open position such that it passes 12gpm of water with 1 psi pressure drop. COMPRESSIBLE FLUIDS Subcritical Cv

INCOMPRESSIBLE FLUIDS

Subcritical Cv

1.16Q* Gf P

Q* (GTZ 295* P(P1+P2) Q increases, Cv increases P,P1,P2increases, Cv reduces

Q increases, Cv increases

P increases, Cv reduces

STEP 2. SELECT THE VALVE TYPE

There is a wide range of control valves styles available on today's market. The

following table lists just a few of them, together with some considerations for

choosing a valve.

Shutoff (ANSI Class IV, V & VI)

High Pressure Drops

ANSI Pressure Ratings (typically 150# - 4500#)

Severe Service Trim for high velocity,noise,cavitation&erosion

G L O B E

Range of Alloy Materials

High Performance

Lightweight Valve

High Cv Capacity

Shutoff (ANSI Class IV & VI)

F L Y

ANSI Pressure Ratings (typically 150# - 600#)

Cost (cheaper than other styles)

Valve Cv's higher than Butterfly or Globe

Shutoff (ANSI Class IV & VI)

ANSI Pressure Ratings (typically 150# - 600#)

B A L L

Good for Fibrous Fluids

Low - Med Pressure drop capabilities

Shutoff (ANSI Class IV & VI)

Suitable for higher velocities

E R I C

ANSI Pressure Ratings (typically 150# - 600#)

GLOBE TYPE CONTROL VALVES: MIL RANGE 1 10000 series Double ported top & bottom guided valves (1 to 16, 150# to 1500#) One of the early designs used for high capacity flow, now mainly limited to refinery/UOP applications.
LIMITATIONS

ADVANTAGES

Top & Bottom guiding provides adequate support against side loads. For standard valves, seat leakage is limited to Class II.

V-Ported plug design available for high pressure drops and cavitation control

Higher P, P Shut off, Cv and pressure recovery factor than Single Seated Valves. 21000 Series Single ported top guided valves (1/2 to 2.5, 150# to 2500#) & (3 to 8, 150# to 600#) Most popular control valve used in all industries for standard applications.
LIMITATIONS

ADVANTAGES

Simple Construction.

Unbalanced construction.

Better Leakage Class. Lower Pressure drop capability. 41000 Series Heavy duty balanced cage guided valves (1 to 14, 150# to 2500#) & (16 to 20, 150# to 600#) Used for Critical applications on Power & Fertilizer sectors and in other sectors for high pressure, high pressure drop, large size applications.
LIMITATIONS

ADVANTAGES

Balanced Construction, sizes upto 20 with std. actuators.

Complex Construction, compared to single seated valves.

High allowable Pressure Drops.

Anti Cav/Lo-dB, Multi Cage designs available to handle severe service conditions.

78000 Series Anti-cavitation & low noise multistage valve (1/2 to 6, 600# to 2500#) Mainly in power sector for BFP & Spray systems. Used for Very high pressure drop, Anti cavitation applications in other industries.

FEATURES

Pressure Drop in stages, Can handle high pressure drops without Cavitation, erosion, vibration & noise.

Low Pressure Recovery, eliminates Cavitation.

OTHER CONTROL VALVES IN MIL PRODUCT RANGE

22000 SERIES HAND OPERATED BELLOW SEALED VALVES FOR HANDLING TOXIC / COSTLY FLUIDS. 25000 SERIES TRIP VALVES FOR OIL FIRING SYSTEMS.

C D E

26000 SERIES SPLIT BODY VALVES FOR CORROSIVE FLUIDS. 29000 SERIES MICROPAK VALVES FOR MICROFLOW CONTROL. 50000 SERIES CRYOGENIC VALVES.

70000 SERIES ANGLE VALVES.

I J

81000 SERIES THREE WAY VALVES FOR DIVERTING AND COMBINING APPLICATIONS. 525/535 SERIES SELF ACTUATING VALVES FOR UPSTREAM / DOWNSTREAM PRESSURE CONTROL. SPECIAL VALVES FOR NUCLEAR / DEFENSE APPLICATION. MATIRX SERIES CONTROL VALVES WITH MULTI-STAGE, MULTIPATH, AXIAL FLOW, ANTI-CAVITATION CONTROL VALVE

STEP 3. SELECT THE VALVE SIZE The body size can be chosen by checking the calculated Cv value against the Manufacturers Cv table for the body style selected, keeping in mind the velocity considerations. CLEAN LIQUIDS *RECOMMENDED FLUID VELOCITY (m/sec) 3 to 6 8 to 14 >16 to 2 7 5 3 3

STANDARD SINGLE SEATED HARDENED 10 7 5 5

STANDARD CAGE GUIDED HARDENED 13 13 10

LIQUIDS WITH PARTICLES HARDEN ED 5

RECOMMENDED FLUID VELOCITY (m/sec) 3 to 6 8 to 14 >16 to 2 3 2 2

SINGLE SEATED * : Varies with body material

GAS/STEAM IN CONTINUOS THROTTLING SERVICE (MACH NUMBER < = 0.33) STEAM IN VENT / INTERMITTENT SERVICE (MACH NUMBER <=0.5)

STEP 4. SELECT TRIM SIZE (RATED Cv)

Some valve styles have a number of trim sizes to choose from. You may

consider the following when selecting a trim size: Valve % open at operating condition/s (generally 70 - 80% is recommended) Trim size for future conditions. Trim Characteristic - Equal percent, linear, quick open etc. Example Control Valve Flow Characteristics Minimum 10% open 10% open 5% open 70% open 90% open 50 % open 80% open 25% open 50% open Normal Maximum Rangeability 5:1 8:1 18:1

Quick opening

Linear

Equal percentage

STANDARD TRIM CHARACTERISTIC FOR MIL VALVES

SINGLE/DOUBLE SEATED/CAGE GUIDED VALVES:

LINEAR / EQUAL % / ON-OFF

MULTI STEP / THREE WAY VALVES:

LINEAR ONLY

Lo dB / ANTICAVITATION DESIGN:

LINEAR ONLY

IN ADDITION, WE HAVE CUSTOMISED CHARACTERISTICS CATERING TO SPECIFIC CONTROL REQUIREMENTS.

STEP 5. SELECT FLOW DIRECTION

STANDARD FLOW DIRECTION FOR CONTROL VALVES

SINGLE SEATED VALVES:

FLOW TO OPEN

DOUBLE SEATED VALVES:

FLOW PASSING INTO SEATS

CAGE GUIDED VALVES:

FLOW TO OPEN (Gas / Steam)

FLOW TO CLOSE (Liquids)

MULTISTEP VALVES

FLOW TO OPEN ONLY

ANTI CAVITATION DESIGN

FLOW TO CLOSE ONLY

Lo - dB DESIGN

FLOW TO OPEN ONLY

STEP 6. MATERIAL SELECTION

CONSIDERATIONS

1. FLUID COMPATIBILITY

2. OPERATING PRESSURE / TEMPERATURE

3. CORROSIVE PROPERTIES CHLORIDES, ETC.)

DUE

TO

CONTAMINANTS

(H2S,

4. QUANTITY AND TYPE OF SOLIDS (SAND, SILICA, CATALYST etc.)

5. INSTALLATION ENVIRONMENTAL CONDITIONS

6. TYPE OF EROSION OCCURRING OR EXPECTED (ABRASIVE PARTICLE, CAVITATION, EROSIVE-CORROSIVE, OR HIGH LIQUID VELOCITY IMPINGEMENT).

Correct material selection is essential for reasonable valve life. Process fluid

corrosion, high velocity, erosion, entrained particles, cavitation or other

problems can combine to destroy or consume incorrect specified materials.

Where carbon steel or stainless steel materials are unsuitable for corrosive

process, special alloys should be selected based on material compatibility with

the process fluid. Where erosion exists, harder or more durable materials can

be specified to prolong the valve life.

SELECTION OF BODY MATERIAL Temp. Range (Low) -27C 427C (High) Temp. Range Application

Body Material

ASTM A 216 Gr WCC

(Carbon Steel)

Suited for use in air, saturated/superheated steam & non corrosive oil & gases at moderate temperatures. For low temperature application.

ASTM A 352 Gr LCB

-45C

343C

(Low Carbon Steel) -27C 537C

ASTM A 217 Gr WC6

(Alloy Steel) -27C 565C

High temperature applications involving high pressure steam & other erosive service like flashing.

ASTM A 217 Gr WC9

(Alloy Steel) -254C 815C

High temperature applications involving high pressure steam & other erosive service like flashing.

ASTM A 351 Gr CF8

(Stainless Steel) -254C 815C

Basic low carbon stainless steel used for majority of applications involving corrosive fluids.

ASTM A 351 Gr CF8M

(Stainless Steel)

Modification of CF8 with Molybdenum added. Due to its superior corrosion resistance, CF8M is widely used in chemical processing industries Oxidising agents, all suplphuric acids at room temperature. Free Cl2 or acids solutions cupric salts; oxidizing agents. or Hydrochloric, sulphuric acids; chloride gas. phosphoric, wet hydrogen

Alloy -20 -45C -195C -195C 315C 371C 371C

Hastelloy C

Hastelloy B

Monel

-195C -195C

485C 260C

Alkalis, Salts, Foods, Organics, air free acids, reducing agents. Hot concentrated caustic, alkaline or neutral salts and reducing

Nickel

CASTING V/S. FORGING SPECIFICATIONS Castings ASTM A 216 Gr. WCB / WCC ASTM A 217 Gr. WC6 ASTM A 182 Gr. F11 ASTM A 182 Gr. F22 ASTM A 182 Gr. 5a ASTM A 182 Gr. F316 ASTM A 217 Gr. WC9 ASTM A 217 Gr. C5 ASTM A 351 Gr. CF8M Forgings ASTM A 105

General Classification Carbon Steel

Alloy Steel, 1 Cr Mo Alloy Steel, 2 Cr 1 Mo Alloy Steel, 5 Cr Mo Ty. 316

SELECTION OF TRIM MATERIAL

Stainless steel is generally used as the standard plug and seat ring material in

control valves. However, other materials may need to be considered for

applications requiring the following characteristics:

Hardness

Corrosion resistance

Erosion resistance

Abrasion resistance

High temperature suitability

Hardened trim for severe service applications

SELECTION OF TRIM MATERIAL ASTM Code

Hardness

General Classfn.
14 HRC max.

General Application

SS 316

Max. Temp. Limit. 593C Non-Erosive, Corrosive, Mod. Press. Drop. Most corrosion resistant of 300 series

Bar Stock: ASTM A 479 Ty. 316 Castings: ASTM A 351 Gr. CF8M Bar Stock: ASTM A 479 Ty. 410 400C
35 HRC min.

Corrosive & NonCorrosive Service

Ty. 410 Stainless Steel (Hardened & Tempered) Ty. 416 Stainless Steel (Hardened & Tempered) No.6 Stellite Bar Stock: ASTM A 582 Ty. 416 400C
31-38 HRC

Corrosive & NonCorrosive Service

Hard Facing

650C

38-47 HRC 38-47 HRC 45-50 HRC

Slightly Erosive & Corrosive Service Erosive & Corrosive Service

No.6 Stellite Solid (< 2)

650C

No.5 Colmonoy Hard Facing

650C

No.6 Colmonoy Hard Facing

650C

56-62 HRC

Erosive & Corrosive Service. Corrosion resistance similar to Inconel. Erosive & Corrosive Service. Corrosion resistance similar to Inconel.

General Classfn. Bar Stock: ASTM A 564 Gr. 630 Castings: ASTM A 747 CB7CU1 Casting: ASTM A743 Gr. CA6NM 650C 700-1000 HV After Nitriding Bar Stock: ASTM A276 Ty.440C 400C
58 HRC 28 HRC min. 32 HRC min (H1075) 40 HRC min (H900)

ASTM Code

17.4 PH Stainless Steel

Max. Temp. Limit. 400C Erosive & Corrosive Service

Hardness

General Application

CA6NM Stainless Steel Heat Treated

Erosive & Corrosive Service. With case hardening, excellent for high temperature service. Very Erosive & NonCorrosive Service

Ty. 440C Stainless Steel. Hardened

STANDARD TRIM MATERIAL FOR MIL VALVES

SINGLE SEATED / DOUBLE SEATED VALVES: PLUG / SEAT : SS 316 or SS 316 with Stelliting on seating surface or SS 316 with complete stelliting.

CAGE GUIDED / MULTI STEP VALVES: High Performance material is standard as these valves are designed specifically for severe service conditions.
MULTISTEP VALVE

CAGE GUIDED VALVE

Plug : 17.4 PH / CA6NM Plug : 440 C Seat : SS316 + Stellite Seat : SS316 + Stellite Cage : CA 6 NM Nitrided Liner/Spacer : 17.4 PH Other common trim material offered by MIL: SS304L/316L/316L Urea Grade/ HAC, HAB, Alloy20, Monel, HVD1, Feralium, Inconel, APX etc.

GUIDE BUSH Application Most common in Carbon Steel and Chrome-Moly steel valves. Most common in Stainless Steel valves Carbon Steel / Chrome-Moly steel valves in high temperatures.

Material

440 C

Stellite 6

Guides generally should differ in hardness by min. 5-10 HRC from the stem material

GLAND PACKING Temp. Range -27 deg C to 180 deg C Application

Material

PTFE in standard bonnet

PTFE in Extended bonnet

-195 deg C to 232 deg C -27 deg C to 400 deg C

All services except molten alkali, hot hydrofluoric acid and oxygen All services except strong oxidizers

Graphite in standard bonnet

Graphite in Extended bonnet

-195 deg C to 566 deg C

Other considerations: Lubricator & Isolation valve: essentially obsoleted by modern self-lubricating packing.

In high temperature service, standard bonnet with Grafoil is less expensive than extended bonnet with Teflon.

STEP 7. SELECT BONNET TYPE Temp. Range -27 deg C to 400 deg C

Type

Standard bonnet

Extended bonnet

-195 deg C to -27 deg C - 400 deg C to 566 deg C

Other considerations: Finned bonnets for high temperature service are being obsoleted in favour of plain extension bonnet which has equivalent heat dissipation properties and is less complicated and expensive.

STEP 8. SELECT BODY RATING

Once you have chosen the body material you can select the ANSI body rating required by checking the process temperature and maximum process pressure against the appropriate ANSI B16.34 table. Working Pressure in psig ANSI 150# ANSI 600# 1 2 1 2 1 2 1 2 ANSI 900# 1 2 1 2 ANSI 300# ANSI 1500# ANSI 2500#

Temp.

38

290 275 750 720 1500 1440 2250 2160 3750 3600 6250 6000 260 235 750 620 1500 1240 2250 1860 3750 3095 6250 5160

93

149 230 215 730 560 1455 1120 2185 1680 3640 2795 6070 4660

204 200 195 705 515 1410 1025 2115 1540 3530 2570 5880 4280 1995 1435 3325 2390 5540 2980 1815 1355 3025 2255 5040 3760 1705 1305 2840 2170 4730 3620 1235 1265 2060 2110 3430 3520 515 700 155 1245 860 1050 260 2075 1430 3460 1750 430 2915

260 170 170 665 480 1330 955

316 140 140 605 450 1210 900

0 80 50 20 50 350 105 170 415 345 830 410 420 825 845

371 110 110 570 430 1135 870

427 80

482 50

00 537 20

1. ASTM A 216 Gr. WCC

2. ASTM A 351 Gr. CF8M

STEP 9. SELECT END CONNECTION TYPE Available through 2, 600# lb, limited to corrosive service. Most applicable to high pressure, high temperature, hazardous fluid or vibrating systems. Socket weld (Up to 2, specify pipe schedule) Butt weld (Above 2, specify pipe schedule) Most common connection due to easy installation / removal. Raised Face (In all sizes, ANSI 150#-ANSI 2500#, excellent for general application and most common connection used) Ring Joint (In all sizes, ANSI 150#-ANSI 2500#, recommended for higher pressure service) Common in low pressure rotary valves.

Threaded

Welded

Flanged

Flangeless

END CONNECTIONS FOR MIL VALVES ANSI RF RTJ T&G FF

FLANGED

DIN

PN PN PN PN PN PN

6,10,16 25,40 64 100 160,250 320,400 BUTT WELD

WELD END

ANSI

Socket WELD

Threaded ** - BS, JIS STANDARDS CAN BE GIVEN

STEP 10. SELECT SHUT-OFF CLASS REQUIRED

Control valve seat leakage can be an important factor in the selection of a

control valve. Leakage class per ANSI Standard B16.104 typically rates seat

leakage. ANSI Class IV is standard for most metal seated control valves.

Tighter shutoff can be achieved by using a soft seat (ANSI Class VI).

ANSI Class V shutoff can be specified for applications requiring tight shutoff in

applications where a soft seat cannot be used due to high temperature.

eg. High temperature steam.

Class I

A modification of any Class II, III or IV valve where design intent is the same

as the basic class, but by agreement between user and supplier, no test is

required.

Class II

This class establishes the maximum permissible leakage generally associated

with commercial double-port, double-seat control valves or balanced single-

port control valves with a piston ring seal and metal-to-metal seats.

Class III

This class establishes the maximum permissible leakage generally associated

with Class II, but with a higher degree of seat and seal tightness.

NOTE: Pressure-balanced valves typically meet Class II and Class III leakage

when used with a metal seat and metal or resilient seals.

Class IV

This class establishes the maximum permissible leakage generally associated

with commercial unbalanced single-port, single-seat control valves and

balanced single-port control valves with extra tight piston rings or other sealing

means and metal-to-metal seats. With globe or rotary valve, a bubble-tight

Class IV leakage can be specified using an elastomeric insert configuration

(commonly referred to as a soft seat). However, there are some soft seat

limitations to remember, such as temperature and pressure.

Class V

This class is usually specified for critical applications where a closed

control valve, without a blocking valve, may be required for long periods

of time with high differential pressure across the seating surfaces. It

requires special manufacturing assembly and testing techniques. This

class is generally associated with metal seat, unbalanced single-port, single

seat control valves or balanced single port designs with exceptional seat and

seal tightness.

NOTE: Pressure-balanced trim can achieve Class IV or Class V leakage when

used with a soft seat and exceptionally tight resilient seals.

Class VI

This class establishes the maximum permissible seat leakage generally

associated with resilient seating control valves either unbalanced or balanced

single port with O-rings or similar gapless seals.

Seat Leakage Classifications (In accordance with ANSI / FCI 70.2) Maximum leakage allowable Test medium Test pressure 0.5% of rated capacity Pressure is applied to valve inlet, with outlet open to atmosphere or connected to a low head-loss measuring device, full normal closing thrust provided by actuator. As above As above Testing procedures required for establishing rating

Leakage class designation

II

Air or water at 50 to 125 F (10 to 52 C)

45 to 60 psi (3.1 to 4.1 bar)or maximum operating differential whichever is lower

III 0.01% of As above As above rated capacity Water at 50 to 125 F (10 to 52 C)

0.1% of rated capacity

As above As above

IV

0.0005 liters per minute of water per inch (mm) of port diameter per psi (bar) differential. Maximum service pressure drop across valve plug, not to exceed ANSI body rating. 100 psi (6.9 bar) pressure drop minimum.

Pressure applied to valve inlet after filling entire body cavity and connected piping with water and stroking valve plug closed. Use net specified maximum actuator thrust, but no more, even if available during test. Allow time for leakage flow to stabilize.

VI

Not to exceed amounts shown in Class VI Seat Leakage Allowance table based on port (orifice) diameter.

Air or nitrogen at 50 to 125 F (10 to 52 C)

50 psig (3.4 bar) or maximum rated differential pressure across valve plug, whichever is lower.

Actuator should be adjusted to operating conditions specified with full normal closing thrust applied to valve plug set. Allow time for leakage flow to stabilize and use suitable measuring devices.

LEAKAGE CLASS FOR MIL VALVES (AS PER ANSI/FCI 70.2)

SINGLE SEATED VALVES:

STANDARD : CLASS IV OPTIONAL : CLASS V & CLASS VI

DOUBLE SEATED VALVES:

STANDARD : CLASS II OPTIONAL : CLASS IV & CLASS VI

CAGE GUIDED VALVES:

STANDARD : Class III,*Class IV (Elastomer Seals) OPTIONAL : CLASS V

MULTISTEP VALVES:

STANDARD : CLASS V OPTIONAL : CLASS VI

STEP 11. ACTUATOR SELECTION

The purpose of an actuator is to provide a force to allow the valve to open and

close as required. Different types of actuator available. The one you select

may depend on the application requirements and/or the type of plant which it

is to be supplied to. Pneumatic Operated Spring Diaphragm Piston Cylinder Electrical Electro-Hydraulic Manual Hand Wheel High Performance Servo Actuator Spring Return Type

PNEUMATIC ACTUATOR Spring less Type

Fail Close Stay put (Using Air Lock) Fail Open

SPRING DIAPHRAGM

PNEUMATIC ACTUATOR

Pneumatic actuators are generally simpler, less costly, and easier to install and maintain.

With no electricity, and thus no spark potential, deployment of pneumatic actuators in hazardous classified areas is a popular choice; but dont ignore that many control valves are accessorized with solenoid valves, limit switches, or electronic controllers.

The simplicity of pneumatic actuators makes them easy to adapt to fail-open or fail-closed configurations. However, depending on the pneumatic actuator type, fail-in-place configurations can be complex.

Most plants have air supply lines running throughout the plant making it relatively easy to connect a new actuator.

A. SPRING DIAPHRAGM ACTUATORS: are common on globe-style control valves requiring infinite positioning. They usually include an opposing spring to provide fail-safe action.

ADVANTAGES OF DIAPHRAGM ACTUATORS OVER PISTON CYLINDER ACTUATORS

Simple in construction, no moving parts, much less maintenance.

Piston requires frequent changes of O rings and seals, In the event of any O ring damage, air will leak.

Any slight moisture content in the air can corrode the cylinder inside, any pitting in the cylinder will start air leak and damage the seals.

Fail safe action inherent for diaphragm actuators, Backup system required for piston cylinder. Back up system with volume tank, 3-way transfer valves, NRV, etc. complicates the instrumentation system.

Only spring diaphragm has ability to act without a positioner. Spring ranges that match controller output signal ranges doesnot require positioner.

B. PISTON

Pneumatic pressure is set on one side of the piston plate and varied on the other to effect motion. Advantages are fast response, flexibility high power-tosize ratio. Disadvantage is positioner prerequisite and lack of inherent fail safe action.

C. CYLINDER

Pneumatic pressure acts on the cylinder plate causing stem movement, an opposing spring provides returning force. Primary use 'is for on-off service. Advantages are high power-to-size ratio and positive fail safe action. Disadvantage is throttling requires double acting positioner.

D.DOUBLE ACTING CYLINDER

Similar to piston actuator but generally utilizes a double acting positioner to vary the pneumatic pressure on both sides of the plate. Advantages and disadvantages are the same as the piston actuator.

E. ELECTRO HYDRAULIC

Double acting servo-valve loads and unloads hydraulic pressure from both sides of a piston plate. Advantages are fast response and high pressure drop capability. Disadvantage is external hydraulic source requirement.

F. HANDWHEEL

Sometimes employed with control valve bodies for a precise manual control or when a pneumatic actuator is to be added later.

STEP 12. SELECTION OF ACCESSORIES.

1. POSITIONER (Valve mounted)

A positioner is a device, pneumatic, electro-pneumatic or digital, which, by using a control signal precisely positions the moving parts of a control valve in accordance with the signal value.

Positioners may be used for the following reasons:

Permit greater accuracy & process control

Maintain position regardless of changing forces

Handle high air pressures

Increase speed of operation

Permit faster speed of response

Change characteristics

Provide simple adjustments including split ranging

A. Pneumatic - most common type:

Usually, operates on a 3-15 psi input signal (3-9,3-27,6-30,9-15 also used)

B. Electropneumatic - Operates on a 4-20 mA input signal

2. ELECTROPNEUMATIC TRANSDUCER (Mounted on or off the valve)

Used to convert a 4-20 mA electrical input signal to either a 3-15 psi or a 6-30 psi pneumatic output signal.

The pneumatic output signal is used either to directly actuate the valve or is used as a positioner input signal.

3. CONTROLLER: It is a device whose input is indicative of the valve of and process variable and whose output initiates valve position changes to maintain the set-point valve of that process variable. : Mounted on or off valve

A. Pressure Controller

B. Temperature Controller : Mounted on or off valve

C. Liquid level controller : Mounted on liquid containing vessel

4. SOLENOID VALVE (Valve mounted)

Commonly 3-way type valve used in on-off service: when solenoid is energized, air supply is applied directly to the actuator completely opening or closing the valve: when de-energized, actuator pressure is vented to atmosphere allowing the actuator spring to fully stroke the valve to the opposite position.

Solenoid valves are used in as the control mechanism to open or close the valve in on/off applications where a positioner is not required.

5. VOLUME BOOSTER (Valve mounted)

Pneumatic device whose output volume is greater than its input signal thus increasing valve stroking speed.

6. AIR SET (Valve mounted)

Supply air pressure reducing regulator (with internal filter and relief valve) used in conjunction with any of the above air consuming devices. Air filters are used upstream of the positioner to remove oil, moisture and foreign material from the process air entering the positioner.

7. LOCK UP VALVE (Valve mounted)

Pneumatic relay which locks in the actuator pressure during loss of plant air supply causing the valve to fail-in-last-position.

8. TRANSFER VALVE (Valve mounted)

Pneumatic relay used in conjunction with a volume tank to transfer volume tank pressure to a springless actuator to ensure proper valve failure during loss of plant air.

9. VOLUME TANK

Mounted on or off the valve; capacity tanks or accumulators used to store air pressure f or transfer to a springless actuator to ensure proper valve failure during loss of plant air.

10. LIMIT SWITCHES

Valve mounted: Mechanical device which trips electrical switches at set position of valve stroke.

11. TRAVEL STOP

Mounted in the actuator; mechanical stops which valve travel, generally to prevent full closure

12. LO-DB PLATE & CARTRIDGES

Mounted downstream of valve multistage, multi port devices which effectively reduce valve noise upto 20 dbA by increasing the valve outlet pressure.

13. HANDWHEELS (Valve mounted)

Handwheels allow the valve to be switched from automatic to manual control. Sometimes used as a built-in travel stop.

SEVERE SERVICE CONSIDERATIONS HIGH VELOCITY HIGH NOISE CAVITATION FLASHING

HIGH PRESSURE DROP EXTREME TEMPERATURE EROSIVE

Severe service generally applies to applications showing any one or more of the above characteristics. Severe service applications can be detrimental to your valve and surrounding equipment, and greatly reduce the valve service life, if they are not taken into account when sizing and selecting a valve.

CAVITATION

P1 P2 PV PVC

A liquid flow can generally be treated as being incompressible if there is no vapour formation. However, vapour bubbles are produced if the local static pressure falls below the fluid vapour pressure. In the event that the pressure recovery is sufficient to raise the static pressure above the vapour pressure, then the vapour bubbles will collapse this process being known as cavitation. Collapsing vapour bubbles release extremely high levels of energy and noise. If these bubbles implode in close proximity to a solid surface then the energy released tears away the material leaving a rough, pitted surface. From the outside, this effect can sound like a high-pitched hissing for incipient cavitation, to a metallic rattling sound for fully developed cavitation.

The effects of cavitation (depending on its severity) include the following:

Pitting and erosion

Noise & vibration

Corrosion

Valve failure

A combination of the above

Cavitation damage may be controlled by using hardened materials in valve construction or by using a cavitation reducing/eliminating trim in the valve.

FLASHING

P1 PV PVC P2

If the downstream pressure on the process fluid is equal to or less than its vapour pressure, the vapour bubbles created at the vena contracta do not collapse, resulting in a liquid-gas mixture downstream of the valve. This is commonly called flashing. The result is a two-phase mixture at the valve outlet and in the downstream piping. Velocity of this two-phase flow is usually very high and results in the possibility of erosion of the valve and piping components. Flashing damage is characterised by a smooth, polished appearance. Flashing damage may be controlled through use of the following: Special Valve design ie. expanded outlet

Control velocities

Use hardened materials in valve construction

The cage guided design of trim is used extensively on high duty flashing applications whereby flow is directed over the plug to dissipate the energy within the confines of the trim. Experience has also shown that in case of flashing it is good practice to use a single stage of pressure letdown.

NOISE

It is commonly thought it is the control valve which radiates noise to the

atmosphere. In fact, this is not the case: Control valve noise is generated by

turbulence created in the valve and radiated to the surroundings by the piping vibration of the valve components, and system. Major sources of control valve noise are and

downstream

mechanical

hydrodynamic

aerodynamic fluid noise.

Mechanical noise can result from vibrations caused by the random pressure

fluctuations within the valve body and fluid impingement upon the valve plug.

Vibration can also be produced by valve components resonating at their

natural frequency. Resonant vibration produces high levels of stress that may failure of the valves components. Noise produced by

produce

fatigue

mechanical vibration is usually well below 100 dBA and is described as a

mechanical rattling. Mechanical noise is usually secondary to the damage that

may result to the vibrating part/s.

Cavitation noise similar to a rattling sound, as if gravel were being carried in

the fluid stream is highly localised to the region immediately downstream of

the vena contracta. Reduction or elimination of cavitation is usually necessary

to reduce physical damage to valve components and the piping system, and

to reduce the SPL (sound pressure level).

Flashing noise occurs when a portion of the fluid vaporises without the

subsequent bubble collapse that occurs in cavitation. Noise results from the

deceleration and expansion of the two-phase flow stream. Generally, flashing

noise is significantly lower than cavitation noise, but erosion is often a serious

problem

Hydrodynamic noise is caused by turbulent liquid flow velocity fluctuations that

result from the rapid deceleration of the fluid as the flow area increases

downstream of the vena contracta. Liquid flow noise is generally low and is

usually not a noise problem.

Aerodynamic noise is the major source of valve noise for gaseous service.

The noise level is generally a function of flow stream velocity and mass flow

rate. As the gas flow through a control valves accelerates as it approaches the

vena contracta, high noise levels can be generated even though the outlet

velocity may be as low as Mach 0.4. Aerodynamic noise levels can be above

100 dBA and reach as high as 150 dBA in certain services. Noise and

cavitation can be reduced or eliminated by staging the pressure drop through

the valve.(see below)