Q-1) Explain Inherent and installed characteristics of control valve

Ans:

Inherent characteristic of a control valve:

The inherent characteristic of a valve is the characteristic published by the manufacturer, based
on tests performed in a system where great care is taken to ensure that the pressure drop across
the test valve is held constant at all valve openings and flow rates.

The inherent characteristic, therefore, represents the relationship between valve flow capacity
and valve opening when there are no system effects involved

Installed characteristic of a control valve:

The installed characteristic is the plot of flow against opening of valve using actual pressure
drops experienced in practice.

Due to the fact that in most applications the pressure drop increases as the flow rate drops, the
installed characteristic will normally change from =% towards linear, and from linear towards
quick opening.

Q-2) Explain following terms

a) Rangeability
b) Valve Capacity ( Cv)
c) Trim
d) Yoke
e) Valve stem

Ans:

• Rangeability: Rangeability [R] is calculated as the percentage of the valve fully open
divided by the percentage open position of the valve to give minimum controllable flow.

• Valve Capacity (Cv): The flow capacity of a valve (Cv) is a quantitative rating of its
ability to pass a fluid flow for a set of given pressure and fluid density conditions, defined
as the flow rate of water in gallons per minute through the valve given a constant pressure
drop of 1 PSID

• Trim: High Pressure Control Valve trim consists of three basic items: the stem, ball, and
seat. These are the operative parts that control the flow of liquid and gas through a valve.
They are also the parts most exposed to process elements, and therefore most vulnerable
to wear over time.
 • Yoke: Valves and actuators must be mounted together using a yoke. Yokes are a type of
mounting bracket. It uses a coupling to connect the valve stem and actuator stem as well
as two brackets that hold the actuator and valve together.

• Valve stem: The disc is positioned by the stem, which connects the actuator to the disc.
Typically, stems are forged and threaded or welded to the disc. For valve designs that
require stem packing or sealing to avoid leakage, the fine surface quality of the stem in
the area of the seal is necessary

Q-3) Explain fail safe action

{Air to Open (ATO) and Air to Closed (ATC) valve applications}

Ans:

Fail safe positions are the final position of the control valve during failure of instrument Air and
it can be “Fail open” OR “Fail Close”. Air fail to open means “Fail open (FO)” and Air fail to
close means “fail close (FC)”.

Sometimes it can be FLC (fail last closed) and FLO (Fail last open). Fail last close means fail in
last position and close slowly. Fail last open means fail in last position and open slowly. These
are used during special requirements e.g. To avoid sudden thermal shock in Reactor/Furnaces.

Q-4) List various types of Control valve. Explain any one in detail.

Ans:

(a) Types of Control Valves based on Action:

Control valves operated through pneumatic actuators can be either

(i) air to open.

(ii) air to close.
They are designed such that if the air supply fails, the control valve will be either fully open, or
fully closed, depending upon the safety requirement of the process.

For example, if the valve is used to control steam or fuel flow, the valve should be shut off
completely in case of air failure. On the other hand, if the valve is handling cooling water to a
reactor, the flow should be maximum in case of emergency.

The schematic arrangements of these two actions are shown in Fig. 2. Valve A are air to close
type, indicating, if the air fails, the valve will be fully open. Opposite is the case for valve B.

(b) Types of Control Valves based on Number of plugs:

Control valves can also be characterized in terms of the number of plugs present, as

(i) single-seated valve

(ii) double-seated valve

(c) Flow Characteristics:

It describes how the flow rate changes with the movement or lift of the stem. The shape of the
plug primarily decides the flow characteristics. However, the design of the shape of a control
valve and its shape.
The flow characteristic of a valve is normally defined in terms of

(i) Inherent or ideal characteristics and

(ii) Effective or installed characteristics.

Q-5) Explain need of positioner in control valve.

Ans:
• More accurate control. Since valve positioners know the valve’s exact position, they
provide more precise control than can be achieved by an actuator on its own. In addition,
positioners improve accuracy in the lower part of the valve stroke, where errors are more
common.
• Faster control. Positioners help control valves respond faster to changes in the process
variable, minimizing the amount of time the system is operating above or below the
setpoint.
• Consistent valve position, even with varying pressures. Varying differential pressure
across the valve can indicate instability in the control loop. A positioner is one solution to
help stabilize valve position.
• More flexible configurations and functions. A positioner allows you to put distance
between the controller and the control valve, as well as to use diaphragm or piston-
controlled actuators. You can also switch between direct and reverse control action or
change the flow characteristics when necessary. You can even use one controller for two
valves (i.e., split ranging).
• Minimal effects of friction, which causes hysteresis and dead band. Friction in the valve
stem packing contributes to both hysteresis and dead band, which reduce productivity.

Q-6) Explain various types of Actuators.

Ans:

Hydraulic Actuators:
The hydraulic actuator uses a hydraulic fluid (for example, oil) to energize the actuator and cause
motion. They have a hollow cylindrical tubing or fluid motor, which generates pressure to cause
motion.

Pneumatic Actuators:
The pneumatic actuator uses compressed air as a source of energy for moving the device.
Similar to hydraulic actuators, compressed air enters the cylinder beneath which exerts pressure
on the piston and moves it.
Pneumatic actuators are very precise and accurate of all types of actuators.

Electrical Actuators:
The electrical actuator converts electrical energy into mechanical energy. Typically, a motor is
used as a power for electrical energy into mechanical torque.
Similar to pneumatic actuators, electrical actuators are accurate and precise. They are widely
used in all types of industrial machines.

Thermal Actuators:
The thermal actuators are relatively simpler types of actuators. It uses thermal energy as a source
of energy for movement.
When the temperature rises, the temperature-sensitive material begins to expand; exerting
pressure on the piston.
When the temperature drops, the material begins to compress and starts pulling the piston back to
its normal position.

Linear Actuators:
As the name suggests, the linear actuators produce linear motion (straight line motion). They are
used in applications where lifting, tilting, pushing, and pulling are needed.
Most industrial systems have equipment that moves in a straight line to perform a task. Such
devices require linear actuators for their working.
Linear actuators can be electrical, pneumatic, or hydraulic.

Rotary Actuators:
Rotary actuators provide circular movement as compared to linear actuators.
Most of the rotating devices and equipment in industrial machinery use rotary actuators for their
motion.
Similar to linear actuators, rotary ones too can be electrical, hydraulic, or pneumatic.

Q-7) Explain Boosters in detail.

Q-8) Explain single and double port Control valve.

Ans:

single-seated valve (single Control valve):

A single-seated valve has a single seat and a single plug, in this type of valves the process
pressure would reach on the bottom side of the plug and this will create a force upward in the
valve stem. The actuator in this valve can control this force or it is capable to act against the
force created by process pressure. So the actuator can move or hold the stem downward by
controlling this force. The actuator in this valve must be able to control this force but it is a
difficult task if the valve is big. If the valve is big then the created pressure will be big too and
the actuator must be capable to handle this force, and because of this, the single-seated valve is
not used for high-pressure applications.
features of single-seated valves:
• These valves have a good flow capacity
• Tight shut-off
 • Good rangeability
• Turndown is high and it is the ratio between the maximum and minimum controllable
flow rate
Advantages

• It provides high rangeability and tight shut-off

• A reversible plug is available

Disadvantages

• A large actuator is needed

• Pressure recovery is low
• Only used for small diameter applications
• The force required to drive the stem is high

Double seated valve (double port valve):

A double-seated valve is a top and bottom guided valve and these valves have two plugs and two
seats. In this type of valve, the line pressure acts upward in one plug and downward in the other,
and because of this, the force is balanced. These valves are used for high-pressure applications.
Double port valves are pressure balanced valves and they can close the valve plug against higher
operating pressure. Tight shut off is not possible as in single-seated valves, these valves have fast
flow response and greater capacity than single-seated valves and they are used when tight shut
off is not needed. In this valve, the two ports cannot be opened at the same time.

features of a double-seated valve:

• A small force is needed to move the stem
• It can be used in large diameter applications
• Flow can be diverted

Advantages

• It can be used for larger valves

• It can be used for high flow and high-pressure services

Disadvantages

• Tight shut off is not possible

• Due to the erosion and cavitation, the body parts could wear out
Q-9) What are the main components of a control valve, and how do they work together to control
fluid flow?

Ans:

• Valve Body: The body, sometimes called the shell, is the primary pressure boundary of a
valve. It serves as the principal element of a valve assembly because it is the framework
that holds everything together.

• Valve Bonnet: The cover for the opening in the valve body is the bonnet. In some
designs, the body itself is split into two sections that bolt together. Like valve bodies,
bonnets vary in design. Some bonnets function simply as valve covers, while others
support valve internals and accessories such as the stem, disk, and actuator.

• Valve Trim: The internal elements of a valve are collectively referred to as a valve’s
trim. The trim typically includes a disk, seat, stem, and sleeves needed to guide the stem.
A valve’s performance is determined by the disk and seat interface and the relation of the
disk position to the seat.

• Disk and Seat: For a valve having a bonnet, the disk is the third primary principal
pressure boundary. The disk provides the capability for permitting and prohibiting fluid
flow. With the disk closed, full system pressure is applied across the disk if the outlet side
is depressurized

• Stem: The stem, which connects the actuator and disk, is responsible for positioning the
disk. Stems are typically forged and connected to the disk by threaded or welded joints.
For valve designs requiring stem packing or sealing to prevent leakage, a fine surface
finish of the stem in the area of the seal is necessary. Typically, a stem is not considered a
pressure boundary part.

• Valve Actuator: The actuator operates the stem and disk assembly. An actuator may be a
manually operated hand wheel, manual lever, motor operator, solenoid operator,
pneumatic operator, or hydraulic ram. In some designs, the actuator is supported by the
bonnet. In other designs, a yoke mounted to the bonnet supports the actuator.

• Valve Packing: Most valves use some form of packing to prevent leakage from the space
between the stem and the bonnet. Packing is commonly a fibrous material (such as flax)
or another compound (such as Teflon) that forms a seal between the internal parts of a
valve and the outside where the stem extends through the body.