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Making process control valve choices

Today’s process control valves offer an ever wider range of features and benefits for industries that require precise control over fluids, steam and other gases. With so many control valves to choose from it is important to establish the features that will deliver the most cost-effective design for a particular application.

Control valves are used to manage the flow rate of a liquid or a gas and in-turn control the temperature, pressure or liquid level within a process. As such, they are defined by the way in which they operate to control flow and include globe valves, angle seat, diaphragm, quarter-turn, knife and needle valves, to name a few. In most cases the valve bodies are made from metal; either brass, forged steel or in hygienic applications 316 stainless steel.

Actuators will use an on-board system to measure the position of the valve with varying degrees of accuracy, depending on the application. A contactless, digital encoder can place the valve in any of a thousand positions, making it very accurate, while more rudimentary measurements can be applied to less sensitive designs.

One of the main areas of debate when specifying globe control valve is determining the size of the valve required. Often process engineers will know the pipe diameter used in an application and it is tempting to take that as the control valve’s defining characteristic. Of greater importance are the flow conditions within the system as these will dictate the size of the orifice within the control valve. The pressure either side of the valve and the expected flow rate are essential pieces of information when deciding on the valve design.

Inside the valve body, the actuator design is often either a piston or a diaphragm design. The piston design typically offers a smaller, more compact valve which is also lighter and easier to handle than the diaphragm designs. Actuators are usually made from stainless steel or polyphenolsulpide (PPS), which is a chemically-resistant plastic. The actuator is topped off by the control head or positioner.

Older, pneumatically operated positioners had a flapper/nozzle arrangement and operated on 3-15psi, so no matter what the state of the valve, open closed or somewhere in between, the system was always expelling some compressed air to the atmosphere.

Compressed air is an expensive commodity, requiring considerable energy to generate and when a manufacturing line is equipped with multiple process control valves all venting to the atmosphere, this can equate to a considerable waste of energy. It is important to not only establish the most appropriate valve design, but also a cost-effective solution that takes account of annual running costs.

Modern, digital, electro-pneumatic valves that use micro-solenoid valves to control the air in and out of the actuator have introduced significant improvements for operators. This design means that while the valve is fully open, fully closed or in a steady state, it is not consuming any air. This, and many other engineering improvements, have made substantial advances in both economy and precision.

Flexible designs

Valve seats can be interchangeable within a standard valve body, which allows the valve to fit existing pipework and the valve seat to the sized to the application more accurately. In some cases, this can be achieved after the valve has been installed, which would enable a process change to be accommodated without replacing the complete valve assembly.

Selecting the most appropriate seal materials is also an important step to ensure reliable operation; Steam processes would normally use metal-to-metal seals, whereas a process that included a sterilization stage may require chemically resistant seals.

Improving reliability

Many process control environments offer less than ideal conditions for long-term reliability. Moisture-laden atmospheres, corrosive chemicals and regular wash-downs all have the capacity to shorten the service life of a process Self regulating control valve. One of the potential weaknesses of the actuator is the spring chamber where atmospheric air is drawn in each time the valve operates.

Control valves are generally present whenever fluid flow regulation is required. The three way and angle control valve reliability is critical to the control quality and safety of a plant. An improved dynamic and static valve behaviour would have a major impact on the process output. In order to assess the dynamic performance of the control valve, a computer model of an electro-hydraulic control valve is developed. And the control valve characteristics are investigated through the use of mathematical simulations of the control valve dynamic performance. The results show that the electro-hydraulic driven control valve, which is developed to regulate the mixed-gas pressure in combined cycle power plant, can meet the challenge of the gas turbine.

According to Morita et al. (2007) and Yonezawa et al. (2008), the typical flow pattern around the Knife Gate Valve is transonic [2, 3]. When pressure fluctuations occur, large static and dynamic fluid forces will act on the valves. Consequently, problematic phenomena, such as valve vibrations and loud noises, can occur, with the worst cases resulting in damage of the valve plug and seal [4]. In order to understand the underlying physics of flow-induced vibrations in a steam control valve head, experimental investigations described by Yonezawa et al. (2012) are carried out. Misra et al. (2002) reported that the self-excited vibration of a piping system occurs due to the coincidence of water hammer, acoustic feedback in the downstream water piping, high acoustic resistance at the control valve, and negative hydraulic stiffness at the control valve [5]. Araki et al. (1981) reported that the steam control-valve head oscillation mechanism was forced vibration, while self-excited vibration was not observed [6].

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