CONTROL VALVE HANDBOOK
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1 ONTROL VLVE HNDOOK Third Edition FISHER ONTROLS INTERNTIONL, IN Marshalltown, Iowa U.S.. ernay France Sao Paulo razil Singapore
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3 Preface to Third Edition ontrol valves are an increasingly vital component of modern manufacturing around the world. Well selected and maintained control valves increase efficiency, safety, profitability, and ecology. The ontrol Valve Handbook has been a primary reference for more than 30 years. This third edition is a complete revision and update that includes vital information on control valve performance and the latest technologies. hapter 1 offers an introduction to control valves including definitions for common control valve and instrumentation terminology. hapter 2 develops the vital topic of control valve performance. hapter 3 covers valve and actuator types. hapter 4 describes digital valve controllers, analog positioners, boosters, and other control valve accessories. hapter 5 is a comprehensive guide to selecting the best control valve for an application. hapter 6 covers the selection and use of special control valves. hapter 7 covers desuperheaters, steam conditioning valves, and turbine bypass systems. hapter 8 offers typical control valve installation and maintenance procedures. hapter 9 includes information on control valve standards and approval agencies throughout the world. hapter 10 offers useful tables of engineering reference data. hapter 11 includes piping reference data. hapter 12 is a handy resource for common conversions. The ontrol Valve Handbook is both a textbook and a reference on the strongest link in the control loop: the control valve and its accessories. This book includes extensive and proven knowledge from leading experts in the process control field including contributions from the IS and the rane ompany. iii
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5 Table of ontents hapter 1. Introduction to ontrol Valves What Is ontrol Valve? Process ontrol Terminology Sliding-Stem ontrol Valve Terminology Rotary-Shaft ontrol Valve Terminology ontrol Valve Functions and haracteristics Terminology Other Process ontrol Terminology hapter 2. ontrol Valve Performance Process Variability Dead and ctuator-positioner Design Valve Response Time Valve Type nd haracterization Valve Sizing Economic Results Summary hapter 3. Valve and ctuator Types ontrol Valves Globe Valves Single-Port Valve odies alanced-plug age-style Valve odies High apacity, age-guided Valve odies Port-Guided Single-Port Valve odies Double-Ported Valve odies Three-Way Valve odies v
6 Table of ontents Rotary Valves utterfly Valve odies V-Notch all ontrol Valve odies Eccentric-Disk ontrol Valve odies Eccentric-Plug ontrol Valve odies ontrol Valve End onnections Screwed Pipe Threads olted Gasketed Flanges Welding End onnections Valve ody onnets Extension onnets ellows Seal onnets ontrol Valve Packing PTFE V-Ring Laminated and Filament Graphite US Regulatory Requirements for Fugitive Emissions haracterization of age-guided Valve odies haracterized Valve Plugs Valve Plug Guiding Restricted-apacity ontrol Valve Trim ctuators Diaphragm ctuators Piston ctuators Electrohydraulic ctuators Manual ctuators Rack and Pinion ctuators Electric ctuators hapter 4. ontrol Valve ccessories Positioners Other ontrol Valve ccessories Limit Switches Solenoid Valve Manifold Supply Pressure Regulator Pneumatic Lock-Up Systems Fail-Safe Systems for Piston ctuators Electro-Pneumatic Transducers Electro-Pneumatic Valve Positioners P Diagnostic Software hapter 5. ontrol Valve Selection Valve ody Materials Designations for the High Nickel lloys Pressure-Temperature Ratings for Standard lass STM 216 Grade W Valves vi
7 Table of ontents STM 217 Grade W9 Valves STM 217 Grade 5 Valves STM 351 Grade F3 Valves STM 351 Grade F8M and STM 479 Grade UNS S31700 Valves Pressure-Temperature Ratings for STM 216 ast Iron Valves Pressure-Temperature Ratings for STM 61 and 62 ast ronze Valves lass Designation and PN Numbers Face to Face Dimensions for Flanged Globe Style ontrol Valves Face to Face Dimensions for uttweld End Globe Style ontrol Valves Face to Face Dimensions for Socket Weld End Globe Style ontrol Valves Face-to-Face Dimensions for Screwed-End Globe-Style ontrol Valves Face-to-enterline Dimensions for Raised Face Globe-Style ngle ontrol Valves Face-to-Face Dimensions for Separable Flanged Globe-Style ontrol Valves Face-to-Face Dimensions for Flangeless, Partial-all ontrol Valves Face-to-Face Dimensions for Single Flange (Lug-Type) and Flangeless (Wafer-Type) utterfly ontrol Valves Face-to-Face Dimensions for High Pressure utterfly Valves with Offset Design Wear & Galling Resistance hart Of Material ombinations ontrol Valve Seat Leakage lassifications lass VI Maximum Seat Leakage llowable Typical Valve Trim Material Temperature Limits Service Temperature Limitations for Elastomers mbient Temperature orrosion Information Elastomer Information Fluid ompatibility ontrol Valve Flow haracteristics Flow haracteristics Selection of Flow haracteristic Valve Sizing Sizing Valves for Liquids bbreviations and Terminology Equation onstants Determining Fp, the Piping Geometry Factor Determining qmax (the Maximum Flow Rate) or Pmax (the llowable Sizing Pressure Drop) Determining qmax (the Maximum Flow Rate) Determining Pmax (the llowable Sizing Pressure Drop) Liquid Sizing Sample Problem Sizing Valves for ompressible Fluids vii
8 Table of ontents Determining xtp, the Pressure Drop Ratio Factor ompressible Fluid Sizing Sample Problem No ompressible Fluid Sizing Sample Problem No Representative Sizing oefficients for Single Ported Globe Style Valve odies Representative Sizing oefficients for Rotary Shaft Valves ctuator Sizing Globe Valves Unbalance Force Typical Unbalance reas of ontrol Valves Force to Provide Seat Load Packing Friction Typical Packing Friction Values D. dditional Forces ctuator Force alculations Rotary ctuator Sizing Torque Equations reakout Torque Dynamic Torque Typical Rotary Shaft Valve Torque Factors V Notch all Valve with omposition Seal High Performance utterfly Valve with omposition Seal Maximum Rotation Non-Destructive Test Procedures Magnetic Particle (Surface) Examination Liquid Penetrant (Surface) Examination Radiographic (Volumetric) Examination Ultrasonic (Volumetric) Examination avitation and Flashing hoked Flow auses Flashing and avitation Valve Selection for Flashing Service Valve Selection for avitation Service Noise Prediction erodynamic Hydrodynamic Noise ontrol Noise Summary Packing Selection Packing Selection Guidelines for Sliding Stem Valves Packing Selection Guidelines for Rotary Valves hapter 6. Special ontrol Valves High apacity ontrol Valves Low Flow ontrol Valves High-Temperature ontrol Valves ryogenic Service Valves viii
9 Table of ontents ustomized haracteristics and Noise batement Trims ontrol Valves for Nuclear Service in the US Valves Subject to Sulfide Stress racking hapter 7. Steam onditioning Valves Understanding Desuperheating Technical spects of Desuperheating Typical Desuperheater Designs Fixed Geometry Nozzle Design Variable Geometry Nozzle Design Self-ontained Design Steam tomized Design Geometry-ssisted Wafer Design Understanding Steam onditioning Valves Steam onditioning Valve Designs Feedforward Design Manifold Design Pressure-Reduction-Only Design Understanding Turbine ypass Systems Turbine ypass System omponents Turbine ypass Valves Turbine ypass Water ontrol Valves Electro-Hydraulic System hapter 8. Installation and Maintenance Proper Storage and Protection Proper Installation Techniques Read the Instruction Manual e Sure the Pipeline Is lean Inspect the ontrol Valve Use Good Piping Practices ontrol Valve Maintenance Reactive Maintenance Preventive Maintenance Predictive Maintenance ctuator Diaphragm Stem Packing Seat Rings Grinding Metal Seats Replacing Seat Rings ench Set hapter 9. Standards and pprovals ontrol Valve Standards merican Petroleum Institute (PI) ix
10 Table of ontents merican Society of Mechanical Engineers (SME) European ommittee for Standardization (EN) European Industrial Valve Standards European Material Standards European Flange Standards Fluid ontrols Institute (FI) Instrument Society of merica (IS) International Electrotechnical ommission (IE) International Standards Organization (ISO) Manufacturers Standardization Society (MSS) NE International Product pprovals for Hazardous (lassified) Locations References anadian Standards ssociation (S) Standards European ommittee for Electrotechnical Standardization (ENELE) Standards Instrument Society of merica (IS) Standards International Electrotechnical ommission (IE) Standards National Electrical Manufacturer s ssociation (NEM) Standards National Fire Protection ssociation (NFP) Standards North merican pprovals pproval gencies Types of Protection Nomenclature Hazardous Location lassification Temperature ode NEM Enclosure Rating General Locations Hazardous (lassified) Locations S Enclosure Ratings Intrinsically Safe pparatus Entity oncept S System Parameter oncept Loop Schematic (ontrol Drawing) omparison of Protection Techniques Explosion proof Technique dvantages of this Technique Disadvantages of this Technique Installation Requirements Intrinsically Safe Technique dvantages of this Technique Disadvantages of this Technique Dust Ignition proof Technique Non Incendive Technique dvantages of this Technique Disadvantages of this Technique x
11 Table of ontents European and sia/pacific pprovals pproval gencies ENELE pprovals Types of Protection Flame proof Increased Safety Intrinsically Safe Non Incendive Nomenclature Hazardous Location lassification Group Zone Temperature ode IE Enclosure Rating NEM and IE Enclosure Rating omparison omparison of Protection Techniques Flame proof Technique dvantages of this Technique Disadvantages of this Technique Increased Safety Technique dvantages of this Technique Disadvantages of this Technique Intrinsically Safe Technique dvantages of this Technique Disadvantages of this Technique Type n Technique dvantages of this Technique Disadvantages of this Technique hapter 10. Engineering Data Standard Specifications For Valve Materials Valve Materials Properties for Pressure ontaining omponents Physical onstants of Hydrocarbons Specific Heat Ratio (K) Physical onstants of Various Fluids Refrigerant 717 (mmonia) Properties of Water Properties of Saturated Steam Properties of Superheated Steam Velocity of Liquids in Pipe Flow of Water Through Schedule 40 Steel Pipe Flow of ir Through Schedule 40 Steel Pipe alculations for Pipe Other than Schedule xi
12 Table of ontents hapter 11. Pipe Data Pipe Engagement arbon and lloy Steel Stainless Steel merican Pipe Flange Dimensions Diameter of olt ircle Inches merican Pipe Flange Dimensions Number of Stud olts and Diameter in Inches merican Pipe Flange Dimensions Flange Diameter Inches DIN Standards merican Pipe Flange Dimensions Flange Thickness for Flange Fittings DIN ast Steel Flange Standard for PN DIN ast Steel Flange Standard for PN DIN ast Steel Flange Standard for PN DIN ast Steel Flange Standard for PN DIN ast Steel Flange Standard for PN DIN ast Steel Flange Standard for PN DIN ast Steel Flange Standard for PN DIN ast Steel Flange Standard for PN DIN ast Steel Flange Standard for PN hapter 12. onversions and Equivalents Length Equivalents Whole Inch Millimeter Equivalents Fractional Inches To Millimeters dditional Fractional/Decimal Inch Millimeter Equivalents rea Equivalents Volume Equivalents Volume Rate Equivalents Mass onversion Pounds to Kilograms Pressure Equivalents Pressure onversion Pounds per Square Inch to ar Temperature onversion Formulas Temperature onversions P.I. and aumé Gravity Tables and Weight Factors Equivalent Volume and Weight Flow Rates of ompressible Fluids Viscosity onversion Nomograph Other Useful onversions Metric Prefixes and Symbols Subject Index xii
13 hapter 1 Introduction to ontrol Valves What Is ontrol Valve? Process plants consist of hundreds, or even thousands, of control loops all networked together to produce a product to be offered for sale. Each of these control loops is designed to keep some important process variable such as pressure, flow, level, temperature, etc. within a required operating range to ensure the quality of the end product. Each of these loops receives and internally creates disturbances that detrimentally affect the process variable, and interaction from other loops in the network provides disturbances that influence the process variable. To reduce the effect of these load disturbances, sensors and transmitters collect information about the process variable and its relationship to some desired set point. controller then processes this information and decides what must be done to get the process variable back to where it should be after a load disturbance occurs. When all the measuring, comparing, and calculating are done, some type of final control element must implement the strategy selected by the controller. The most common final control element in the process control industries is the control valve. The control valve manipulates a flowing fluid, such as gas, steam, water, or chemical compounds, to compensate for the load disturbance and keep the regulated process variable as close as possible to the desired set point. Many people who talk about control valves or valves are really referring to a control valve assembly. The control valve assembly typically consists of the valve body, the internal trim parts, an actuator to provide the motive power to operate the valve, and a variety 1
14 hapter 1. Introduction to ontrol Valves of additional valve accessories, which can include positioners, transducers, supply pressure regulators, manual operators, snubbers, or limit switches. Other chapters of this handbook supply more detail about each of these control valve assembly components. Whether it is called a valve, control valve or a control valve assembly, is not as important as recognizing that the control valve is a critical part of the control loop. It is not accurate to say that the control valve is the most important part of the loop. It is useful to think of a control loop as an instrumentation chain. Like any other chain, the whole chain is only as good as its weakest link. It is important to ensure that the control valve is not the weakest link. Following are definitions for process control, sliding-stem control valve, rotary-shaft control valve, and other control valve functions and characteristics terminology. NOTE: Definitions with an asterisk (*) are from the IS ontrol Valve Terminology draft standard S75.05 dated October, 1996, used with permission. Process ontrol Terminology ccessory: device that is mounted on the actuator to complement the actuator s function and make it a complete operating unit. Examples include positioners, supply pressure regulators, solenoids, and limit switches. ctuator * : pneumatic, hydraulic, or electrically powered device that supplies force and motion to open or close a valve. 2 ctuator ssembly: n actuator, including all the pertinent accessories that make it a complete operating unit. acklash: The general name given to a form of dead band that results from a temporary discontinuity between the input and output of a device when the input of the device changes direction. Slack, or looseness of a mechanical connection is a typical example. apacity * (Valve): The rate of flow through a valve under stated conditions. losed Loop: The interconnection of process control components such that information regarding the process variable is continuously fed back to the controller set point to provide continuous, automatic corrections to the process variable. ontroller: device that operates automatically by use of some established algorithm to regulate a controlled variable. The controller input receives information about the status of the process variable and then provides an appropriate output signal to the final control element. ontrol Loop: (See losed Loop.) ontrol Range: The range of valve travel over which a control valve can maintain the installed valve gain between the normalized values of 0.5 and 2.0. ontrol Valve: (See ontrol Valve ssembly.) ontrol Valve ssembly: Includes all components normally mounted on the valve: the valve body assembly, actuator, positioner, air sets, transducers, limit switches, etc. Dead and: The range through which an input signal can be varied, upon reversal of direction, without initiating an observable change in the output signal. Dead band is the name given to a general phenomenon that can apply to any device. For the valve
15 7152 / IL Figure 1-1. Process Dead and assembly, the controller output (O) is the input to the valve assembly and the process variable (PV) is the output as shown in figure 1-1. When the term Dead and is used, it is essential that both the input and output variables are identified, and that any tests to measure dead band be under fully loaded conditions. Dead band is typically expressed as a percent of the input span. Dead Time: The time interval (Td) in which no response of the system is detected following a small (usually 0.25% - 5%) step input. It is measured from the time the step input is initiated to the first detectable response of the system being tested. Dead Time can apply to a valve assembly or to the entire process. (See T 63. ) Disk: valve trim element used to modulate the flow rate with either linear or rotary motion. an also be referred to as a valve plug or closure member. Equal Percentage haracteristic * : n inherent flow characteristic that, for equal increments of rated travel, will ideally give equal percentage changes of the flow coefficient ( v ) (figure 1-2). hapter 1. Introduction to ontrol Valves Final ontrol Element: The device that implements the control strategy determined by the output of the controller. While the final control element can be a damper, a variable speed drive pump, or an on-off switching device, the most common final control element in the process control industries is the control valve assembly. The control valve manipulates a flowing fluid, such as gasses, steam, water, or chemical compounds, to compensate for the load disturbance and keep the regulated process variable as close as possible to the desired set point. First-Order: term that refers to the dynamic relationship between the input and output of a device. first-order system or device is one that has only one energy storage device and whose dynamic transient relationship between the input and output is characterized by an exponential behavior. Friction: force that tends to oppose the relative motion between two surfaces that are in contact with each other. The friction force is a function of the normal force holding these two surfaces together and the characteristic nature of the two surfaces. Friction has two components: static friction and dynamic friction. Static friction is the force that must be overcome before there is any relative motion between the two surfaces. Once relative movement has begun, dynamic friction is the force that must be overcome to maintain the relative motion. Running or sliding friction are colloquial terms that are sometimes used to describe dynamic friction. Stick/slip or stiction are colloquial terms that are sometimes used to describe static friction. Static friction is one of the major causes of dead band in a valve assembly. Gain: n all-purpose term that can be used in many situations. In its most general sense, gain is the ratio of the magnitude of the output change of a given system or device to the magnitude of the input change that caused the output change. Gain has two components: static gain and dynamic gain. Static gain is the gain relationship between the input and output and is an indicator of the ease with which the input can initiate a change in the 3
16 hapter 1. Introduction to ontrol Valves 3449/IL Figure 1-2. Inherent Valve haracteristics output when the system or device is in a steady-state condition. Sensitivity is sometimes used to mean static gain. Dynamic gain is the gain relationship between the input and output when the system is in a state of movement or flux. Dynamic gain is a function of frequency or rate of change of the input. Hysteresis * : The maximum difference in output value for any single input value during a calibration cycle, excluding errors due to dead band. Inherent haracteristic * : The relationship between the flow coefficient and the closure member (disk) travel as it is moved from the closed position to rated travel with constant pressure drop across the valve. Typically these characteristics are plotted on a curve where the horizontal axis is labeled in percent travel and the vertical axis is labeled as percent flow (or v ) (figure 1-2). ecause valve flow is a function of both the valve travel and the pressure drop across the valve, conducting flow characteristic tests at a constant pressure drop provides a systematic way of comparing one valve characteristic design to another. Typical valve characteristics conducted in this manner 4 are named Linear, Equal-Percentage, and Quick Opening (figure 1-2). Inherent Valve Gain: The magnitude ratio of the change in flow through the valve to the change in valve travel under conditions of constant pressure drop. Inherent valve gain is an inherent function of the valve design. It is equal to the slope of the inherent characteristic curve at any travel point and is a function of valve travel. Installed haracteristic * : The relationship between the flow rate and the closure member (disk) travel as it is moved from the closed position to rated travel as the pressure drop across the valve is influenced by the varying process conditions. (See Valve Type and haracterization in hapter 2 for more details on how the installed characteristic is determined.) Installed Valve Gain: The magnitude ratio of the change in flow through the valve to the change in valve travel under actual process conditions. Installed valve gain is the valve gain relationship that occurs when the valve is installed in a specific system and the pressure drop is allowed to change naturally according to the dictates of the overall system. The installed valve gain is equal to the slope of the installed characteristic curve, and is a function of valve travel. (See Valve Type and haracterization in hapter 2 for more details on how the installed gain is determined.) I/P: Shorthand for current-to-pressure (I-to-P). Typically applied to input transducer modules. Linearity * : The closeness to which a curve relating to two variables approximates a straight line. (Linearity also means that the same straight line will apply for both upscale and downscale directions. Thus, dead band as defined above, would typically be considered a non-linearity.) Linear haracteristic * : n inherent flow characteristic that can be repre-
17 sented by a straight line on a rectangular plot of flow coefficient ( v ) versus rated travel. Therefore equal increments of travel provide equal increments of flow coefficient, v (figure 1-2). Loop: (See losed Loop.) Loop Gain: The combined gain of all the components in the loop when viewed in series around the loop. Sometimes referred to as open-loop gain. It must be clearly specified whether referring to the static loop gain or the dynamic loop gain at some frequency. Manual ontrol: (See Open Loop.) Open Loop: The condition where the interconnection of process control components is interrupted such that information from the process variable is no longer fed back to the controller set point so that corrections to the process variable are no longer provided. This is typically accomplished by placing the controller in the manual operating position. Packing: part of the valve assembly used to seal against leakage around the valve disk or stem. Positioner * : position controller (servomechanism) that is mechanically connected to a moving part of a final control element or its actuator and that automatically adjusts its output to the actuator to maintain a desired position in proportion to the input signal. Process: ll the combined elements in the control loop, except the controller. The process typically includes the control valve assembly, the pressure vessel or heat exchanger that is being controlled, as well as sensors, pumps, and transmitters. Process Gain: The ratio of the change in the controlled process variable to a corresponding change in the output of the controller. hapter 1. Introduction to ontrol Valves Process Variability: precise statistical measure of how tightly the process is being controlled about the set point. Process variability is defined in percent as typically (2s/m), where m is the set point or mean value of the measured process variable and s is the standard deviation of the process variable. Quick Opening haracteristic * : n inherent flow characteristic in which a maximum flow coefficient is achieved with minimal closure member travel (figure 1-2). Relay: device that acts as a power amplifier. It takes an electrical, pneumatic, or mechanical input signal and produces an output of a large volume flow of air or hydraulic fluid to the actuator. The relay can be an internal component of the positioner or a separate valve accessory. Resolution: The minimum possible change in input required to produce a detectable change in the output when no reversal of the input takes place. Resolution is typically expressed as a percent of the input span. Response Time: Usually measured by a parameter that includes both dead time and time constant. (See T 63, Dead Time, and Time onstant.) When applied to the valve, it includes the entire valve assembly. Second-Order: term that refers to the dynamic relationship between the input and output of a device. second-order system or device is one that has two energy storage devices that can transfer kinetic and potential energy back and forth between themselves, thus introducing the possibility of oscillatory behavior and overshoot. Sensor: device that senses the value of the process variable and provides a corresponding output signal to a transmitter. The sensor can be an integral part of the transmitter, or it may be a separate component. 5
18 hapter 1. Introduction to ontrol Valves Set Point: reference value representing the desired value of the process variable being controlled. Shaft Wind-Up: phenomenon where one end of a valve shaft turns and the other does not. This typically occurs in rotary style valves where the actuator is connected to the valve closure member by a relatively long shaft. While seal friction in the valve holds one end of the shaft in place, rotation of the shaft at the actuator end is absorbed by twisting of the shaft until the actuator input transmits enough force to overcome the friction. Sizing (Valve): systematic procedure designed to ensure the correct valve capacity for a set of specified process conditions. Travel * : The movement of the closure member from the closed position to an intermediate or rated full open position. Travel Indicator: pointer and scale used to externally show the position of the closure member typically with units of opening percent of travel or degrees of rotation. Trim * : The internal components of a valve that modulate the flow of the controlled fluid. Valve: (See ontrol Valve ssembly.) Volume ooster: stand-alone relay is often referred to as a volume booster or simply booster because it boosts, or amplifies, the volume of air supplied to the actuator. (See Relay.) Stiction: (See Friction.) T 63 (Tee-63): measure of device response. It is measured by applying a small (usually 1-5%) step input to the system. T 63 is measured from the time the step input is initiated to the time when the system output reaches 63% of the final steady-state value. It is the combined total of the system Dead Time (T d ) and the system Time onstant (t). (See Dead Time and Time onstant.) Time onstant: time parameter that normally applies to a first-order element. It is the time interval measured from the first detectable response of the system to a small (usually 0.25% - 5%) step input until the system output reaches 63% of its final steady-state value. (See T 63. ) When applied to an open-loop process, the time constant is usually designated as (Tau). When applied to a closed-loop system, the time constant is usually designated as λ (Lambda). Transmitter: device that senses the value of the process variable and transmits a corresponding output signal to the controller for comparison with the set point. 6 Sliding-Stem ontrol Valve Terminology The following terminology applies to the physical and operating characteristics of standard sliding-stem control valves with diaphragm or piston actuators. Some of the terms, particularly those pertaining to actuators, are also appropriate for rotary-shaft control valves. Many of the definitions presented are in accordance with IS S75.05, ontrol Valve Terminology, although other popular terms are also included. dditional explanation is provided for some of the more complex terms. omponent part names are called out on accompanying figures 1-3 through 1-6. Separate sections follow that define specific rotaryshaft control valve terminology, control valve functions and characteristics terminology, and other process control terminology. ctuator Spring: spring, or group of springs, enclosed in the yoke or actuator casing that moves the actuator stem in a direction opposite to that created by diaphragm pressure. ctuator Stem: The part that connects the actuator to the valve stem
19 hapter 1. Introduction to ontrol Valves LODING PRESSURE ONNE- TION DIPHRGM SING DIPHRGM ND STEM SHOWN IN UP POSITION DIPHRGM PLTE TUTOR SPRING TUTOR STEM SPRING SET SPRING DJUSTOR STEM ONNETOR YOKE TRVEL INDITOR INDITOR SLE W0363-1/IL ONNET GSKET SPIRL WOUND GSKET VLVE PLUG STEM PKING FLNGE TUTOR YOKE LOKNUT PKING PKING OX ONNET 1550/IL GE GSKET VLVE PLUG GE SET RING W0989/IL VLVE ODY SET RING GSKET Figure 1-3. Major omponents of Typical Sliding Stem ontrol Valve ssembly 7
20 hapter 1. Introduction to ontrol Valves DIPHRGM SINGS DIPHRGM ND STEM SHOWN IN DOWN POSITION DIPHRGM PLTE LODING PRESSURE ONNETION TUTOR SPRING TUTOR STEM SPRING SET SPRING DJUSTOR STEM ONNETOR YOKE TRVEL INDITOR INDITOR SLE W0364-1/IL Figure 1-4. Typical Reverse-cting Diaphragm ctuator W0667/IL Figure 1-5. Extension onnet and transmits motion (force) from the actuator to the valve. ctuator Stem Extension: n extension of the piston actuator stem to provide a means of transmitting piston 8 W6434/IL Figure 1-6. ellows Seal onnet motion to the valve positioner (figure 1-7). ctuator Stem Force: The net force from an actuator that is available for actual positioning of the valve plug.
21 hapter 1. Introduction to ontrol Valves INTEGRLLY MOUNTED VLVE POSITIONER YLINDER SEL SEL USHING TUTOR STEM EXTENSION SEL PISTON SEL TUTOR STEM TUTOR STEM EXTENSION PISTON YLINDER YLINDER LOSURE SEL RUER OOT TUTOR STEM SEL YLINDER SEL SEL USHING YOKE STEM ONNETOR TRVEL INDITOR W0319-1/IL Figure 1-7. Typical Double-cting Piston ctuator TRVEL INDITOR SLE ngle Valve: valve design in which one port is co-linear with the valve stem or actuator, and the other port is at a right angle to the valve stem. (See also Globe Valve.) ellows Seal onnet: bonnet that uses a bellows for sealing against leakage around the closure member stem (figure 1 6). onnet: The portion of the valve that contains the packing box and stem seal and can guide the stem. It provides the principal opening to the body cavity for assembly of internal parts or it can be an integral part of the valve body. It can also provide for the attachment of the actuator to the valve body. Typical bonnets are bolted, threaded, welded, pressureseals, or integral with the body. (This term is often used in referring to the bonnet and its included packing parts. More properly, this group of component parts should be called the bonnet assembly.) onnet ssembly: (ommonly onnet, more properly onnet ssembly): n assembly including the part through which a valve stem moves and a means for sealing against leakage along the stem. It usually provides a means for mounting the actuator and loading the packing assembly. ottom Flange: part that closes a valve body opening opposite the bonnet opening. It can include a guide bushing and/or serve to allow reversal of the valve action. ushing: device that supports and/ or guides moving parts such as valve stems. age: part of a valve trim that surrounds the closure member and can provide flow characterization and/or a seating surface. It also provides stability, guiding, balance, and alignment, and facilitates assembly of other parts of the valve trim. The walls of the cage contain openings that usually determine the flow characteristic of 9
22 hapter 1. Introduction to ontrol Valves W0957/IL W0958/IL W0959/IL Figure 1-8. haracterized ages for Globe-Style Valve odies the control valve. Various cage styles are shown in figure 1-8. losure Member: The movable part of the valve that is positioned in the flow path to modify the rate of flow through the valve. losure Member Guide: That portion of a closure member that aligns its movement in either a cage, seat ring, bonnet, bottom flange, or any two of these. ylinder: The chamber of a piston actuator in which the piston moves (figure 1-7). ylinder losure Seal: The sealing element at the connection of the piston actuator cylinder to the yoke. Diaphragm: flexible, pressure responsive element that transmits force to the diaphragm plate and actuator stem. Diaphragm ctuator: fluid powered device in which the fluid acts upon a flexible component, the diaphragm. Diaphragm ase: housing, consisting of top and bottom section, used for supporting a diaphragm and establishing one or two pressure chambers. 10 Diaphragm Plate: plate concentric with the diaphragm for transmitting force to the actuator stem. Direct ctuator: diaphragm actuator in which the actuator stem extends with increasing diaphragm pressure. Extension onnet: bonnet with greater dimension between the packing box and bonnet flange for hot or cold service. Globe Valve: valve with a linear motion closure member, one or more ports, and a body distinguished by a globular shaped cavity around the port region. Globe valves can be further classified as: two-way single-ported; two-way double-ported (figure 1-9); angle-style (figure 1-10); three-way (figure 1-11); unbalanced cage-guided (figure 1-3); and balance cage-guided (figure 1-12). Lower Valve ody: half housing for internal valve parts having one flow connection. The seat ring is normally clamped between the upper valve body and the lower valve body in split valve constructions. Offset Valve: valve construction having inlet and outlet line connections on different planes but 180 degrees opposite each other. Packing ox (ssembly): The part of the bonnet assembly used to seal against leakage around the closure
23 hapter 1. Introduction to ontrol Valves W0467/IL Figure 1-9. Reverse Double-Ported Globe-Style Valve ody W0665/IL Figure Three-Way Valve with alanced Valve Plug W0992/IL W0971/IL Figure Flanged ngle-style ontrol Valve ody member stem. Included in the complete packing box assembly are various combinations of some or all of the following component parts: packing, packing follower, packing nut, lantern ring, packing spring, packing flange, packing flange studs or bolts, packing flange nuts, packing ring, packing wiper ring, felt wiper ring, belleville springs, anti-extrusion ring. Individual Figure Valve ody with age-style Trim, alanced Valve Plug, and Soft Seat packing parts are shown in figure Piston: movable pressure responsive element that transmits force to the piston actuator stem (figure 1-7). Piston Type ctuator: fluid powered device in which the fluid acts upon a movable piston to provide motion to the actuator stem. Piston type actuators (figure 1-7) are classified as either double-acting, so that full power 11
24 hapter 1. Introduction to ontrol Valves / IL E E LOTION OF SRIFIIL ZIN WSHER, IF USED. Figure omprehensive Packing Material rrangements for Globe-Style Valve odies can be developed in either direction, or as spring-fail so that upon loss of supply power, the actuator moves the valve in the required direction of travel. Plug: term frequently used to refer to the closure member. Port: The flow control orifice of a control valve. Retaining Ring: split ring that is used to retain a separable flange on a valve body. Reverse ctuator: diaphragm actuator in which the actuator stem retracts with increasing diaphragm pressure. Reverse actuators have a seal bushing (figure 1-4) installed in the upper end of the yoke to prevent leakage of the diaphragm pressure along the actuator stem. Rubber oot: protective device to prevent entrance of damaging foreign material into the piston actuator seal bushing. Seal ushing: Top and bottom bushings that provide a means of sealing 12 the piston actuator cylinder against leakage. Synthetic rubber O-rings are used in the bushings to seal the cylinder, the actuator stem, and the actuator stem extension (figure 1-7). Seat: The area of contact between the closure member and its mating surface that establishes valve shut-off. Seat Load: The net contact force between the closure member and seat with stated static conditions. In practice, the selection of an actuator for a given control valve will be based on how much force is required to overcome static, stem, and dynamic unbalance with an allowance made for seat load. Seat Ring: part of the valve body assembly that provides a seating surface for the closure member and can provide part of the flow control orifice. Separable Flange: flange that fits over a valve body flow connection. It is generally held in place by means of a retaining ring. Spring djustor: fitting, usually threaded on the actuator stem or into
25 the yoke, to adjust the spring compression. Spring Seat: plate to hold the spring in position and to provide a flat surface for the spring adjustor to contact. Static Unbalance: The net force produced on the valve stem by the fluid pressure acting on the closure member and stem with the fluid at rest and with stated pressure conditions. Stem onnector: The device that connects the actuator stem to the valve stem. Trim: The internal components of a valve that modulate the flow of the controlled fluid. In a globe valve body, trim would typically include closure member, seat ring, cage, stem, and stem pin. Trim, Soft-Seated: Valve trim with an elastomeric, plastic or other readily deformable material used either in the closure component or seat ring to provide tight shutoff with minimal actuator forces. Upper Valve ody: half housing for internal valve parts and having one flow connection. It usually includes a means for sealing against leakage along the stem and provides a means for mounting the actuator on the split valve body. Valve ody: The main pressure boundary of the valve that also provides the pipe connecting ends, the fluid flow passageway, and supports the seating surfaces and the valve closure member. mong the most common valve body constructions are: a) single-ported valve bodies having one port and one valve plug; b) double-ported valve bodies having two ports and one valve plug; c) twoway valve bodies having two flow connections, one inlet and one outlet; d) three-way valve bodies having three flow connections, two of which can be inlets with one outlet (for converging hapter 1. Introduction to ontrol Valves or mixing flows), or one inlet and two outlets (for diverging or diverting flows). The term valve body, or even just body, frequently is used in referring to the valve body together with its bonnet assembly and included trim parts. More properly, this group of components should be called the valve body assembly. Valve ody ssembly (ommonly Valve ody or Valve, more properly Valve ody ssembly): n assembly of a valve, bonnet assembly, bottom flange (if used), and trim elements. The trim includes the closure member, which opens, closes, or partially obstructs one or more ports. Valve Plug: term frequently interchanged with plug in reference to the closure member. Valve Stem: In a linear motion valve, the part that connects the actuator stem with the closure member. Yoke: The structure that rigidly connects the actuator power unit to the valve. Rotary-Shaft ontrol Valve Terminology The definitions that follow apply specifically to rotary-shaft control valves. ctuator Lever: rm attached to rotary valve shaft to convert linear actuator stem motion to rotary force to position disk or ball of rotary-shaft valve. The lever normally is positively connected to the rotary shaft by close tolerance splines or other means to minimize play and lost motion. all, Full: The flow-controlling member of rotary-shaft control valves using a complete sphere with a flow passage through it. The flow passage equals or matches the pipe diameter. 13
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