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Control valve presentation

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Prem kumar

This document provides an overview of control valves, including applicable standards, types of control valves, leakage classes, characteristics, selection criteria, and noise and cavitation controls. It discusses control valve fundamentals like flow characterization using different cage designs, cavitation and flashing issues, and remedies. The document also summarizes Reliance Petroleum's control valve selection process and installed base of control valves from manufacturers like Fisher, ABB, and CCI.

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1 Reliance Petroleum Ltd. The Boss of Control Loop, Final Control Element
2 Reliance Petroleum Ltd. CONTROL VALVE AN OVERVIEW
3 CONTENT - • STANDARDS APPLICABLE FOR CONTROL VALVE • WHAT IS A CONTROL VALVE ? • CONTROL VALVE LEAKAGE CLASS • CONTROL VALVE CHARACTERISTICS • CONTROL VALVE SELECTION & INTERCHANGEABILITY • FLASHING • CAVITATION • ARDUOUS SERVICE VALVE • NOISE REDUCTIONS PRACTICES • VALVE GLAND PACKING & MATERIAL OF CONSTRUCTION • CONTROL VALVE ACTUATOR TODAY’S DISCUSSION
4 Control Valves –Selection , Sizing and Specification • DEP 32.36.01.17- Gen July 1987 & • Basic Process control & Instrumentation Shell M114-1999 • Shell Best Practice –[Ref Process Measurement and Control Devices –Shell Canada Ltd Standard 16-1.2] SHELL REFERENCES
5 ANSI :- AMERICAN NATIONAL STANDARDS INSTITUTE B16.34 :- STEEL VALVES • DEFINES CRITERIA FOR VALVE WALL THICKNESS REQUIREMENTS • DEFINES PRESSURE / TEMPERATURE RATINGS • DEFINE HYDRO-TEST REQUIREMENTS Example :- A351 CF8M ( Material :- 316SST; Temp range :- -425 °F to 1500 °F) A216 WCB ( Material :- Carbon Steel; Temp range:- -20 °F to 1000 °F ) B16.37 :- HYDROSTATIC TEST PROCEDURE • DEFINES REQUIREMENT FOR HYDRO-TEST = 1.5 X MWP MWP = MAXIMUM WORKING PRESSURE B16.104 :- CONTROL VALVE SEAT LEAKAGE CLASSIFICATION • ESTABLISHES TEST PROCEDURES AND SEAT LEAKAGE CLASSES API :- AMERICAN PETROLEUM INSTITUTE SPEC 6B :- DEFINES PIPELINE VALVE SPEC 600 :- STEEL GAGE VALVES, FLANGED BUTT WELDING ENDS CONTROL VALVE STANDARDS
6 NACE :- NATIONAL ASSOCIATION OF CORROSION ENGINEERS NACE MR-01-75 • DEFINES SULFIDE STRESS CRACKING RESISTANCE MATERIAL • MATERIAL COMPLY TO NACE STANDARD ARE CARBON STEEL WITH HEAT TREATMENT SST 302,304,316,17-4PH ALLOY STEEL MONEY, HASTELLOY C • MATERIAL NOT SUITABLE FOR NACE ENVIRONMENT IS CAST IRON CONTROL VALVE STANDARDS
7 ISA :- INSTRUMENT SOCIETY OF AMERICA • DEFINES STANDARDS FOR CONTROL INDUSTRY Example :- VALVE SIZING EQUATIONS. NOISE PREDICTION TECHNIQUE CONTROL SIGNAL 3 - 15 PSIG, 6 - 30 PSIG OSHA :- OCCUPATIONAL SAFETY AND HEALTH ACT DEFINES CRITERIA FOR PERMISSIBLE DURATION FOR EXPOSURE OF NOISE LEVEL CONTROL VALVE STANDARDS
8 WHAT IS A CONTROL VALVE ? CONTROL VALVE This is a device used to modulate flow of process fluid in line by creating a variable pressure drop in the line . Normally the pressure drop is made with respect to the control signal received towards flow condition correction required.
9 TYPE OF CONTROL VALVE Also valves may be further subdivided as shown below BY SHAPE BY INTERNAL BY CHAR. BY GUIDING GLOBE PLUG EQ% TOP BUTTERFLY CAGE LINEAR CAGE ANGLE FULL BALL QUICK OPEN TOP & BOTTOM SLANT SLEEVED PARABOLIC BUSH/BEARING Y TYPE V BALL All Control valve can be divided in two category. 1. Sliding stem ( Globe valve) 2. Rotary shaft ( Quarter turn )
10 WHAT IS VALVE FLOW COEFFICIENT ? VALVE Cv - No. Of US gallon [ USG = 3.7 Ltrs] of water per minute passing through the valve in full open condition with 1 PSI pressure Drop across the valve at 15 deg C temp. So essentially valve Cv is capacity of valve in terms of water which helps us to identify suitable size required for any fluid in any pressure / temp. condition. VALVE Kv - Quantity of water in M3/Hr. at temperature between 5 to 40C that will flow through the valve at a specified travel with a pressure drop of 1 Bar. Kv = 0.856Cv
11 CONTROL VALVE LEAKAGE Control Valve Leakage -Control Valve Leakage - This is basically the fluid which passes through the valve when the valve isThis is basically the fluid which passes through the valve when the valve is fully closed. This value however should not be considered as the valve Cvfully closed. This value however should not be considered as the valve Cv at NIL Opening.at NIL Opening. So this leakage shall depend on the contact of valve plug & seat with theSo this leakage shall depend on the contact of valve plug & seat with the seating force applied for holding the plug over the seat.seating force applied for holding the plug over the seat.
12 CONTROL VALVE LEAKAGE ANSI/FCI 70-2 Test Medium Pressure and temperature Class II Class III Class IV Class V Water Service DP at 10 to 52deg C Port dia. Bubbles per Min. mL per Min. 1 1 0.15 1 - 1/2 2 0.30 2 3 0.45 2 - 1/2 4 0.60 3 6 0.90 4 11 1.70 6 27 4.00 8 45 6.75 Maximum Leakage 0.5% valve capacity at full travel 0.1% valve capacity at full travel 0.01% valve capacity at full travel 0.0005ml/min/psid/in. port dia Class VI Service DP or 50 PSID whichever is lower at 10 to 52deg C Water / Air Service DP or 50 PSID whichever is lower at 10 to 52deg C Air
13 VALVE CHARACTERISTICS Equal %Equal % - Rate of change of flow due to change of valve- Rate of change of flow due to change of valve travel is proportional to earliertravel is proportional to earlier flow.flow. LinearLinear - Rate of change of flow is same to rate of- Rate of change of flow is same to rate of change of valve travelchange of valve travel Quick OpenQuick Open - Full capacity attaining without change of- Full capacity attaining without change of travel after initial openingtravel after initial opening
14 1. CHARACTERISING FLOW1. CHARACTERISING FLOW • Linear CageLinear Cage • Quick Opening CageQuick Opening Cage • Equal Percentage CageEqual Percentage Cage • Modified Equal percentage flowModified Equal percentage flow 2. NOISE ABATEMENT2. NOISE ABATEMENT 3. ANTI CAVITATION3. ANTI CAVITATION TRIM AND CAGE DESIGN
15 CHARACTERIZING FLOW BY CAGE TYPECHARACTERIZING FLOW BY CAGE TYPE
16 CHARACTERIZING FLOWCHARACTERIZING FLOW Equal % Linear % Valve Travel 0 20 40 60 80 100 100 80 60 40 20 0 Cv DesignCv % Quick Opening
17 VALVE SELECTION PROCESS FOLLOWED IN - RPL • If valve sizing does not gives warning of cavitation, flashing or Noise level ( >85dBA) then select standard fisher trim valve. • If valve sizing gives warning of cavitation, flashing or Noise level ( >85dBA) then select arduous service trim of fisher. Example:- For cavitation select CAVITROL III stage 1 to 5 valve or CAVITROL 4 valve. For noise select WHISPER I ,III or WHISPERFLO valve trim. • If suitable fisher product is not available then select valve from ABB or CCI. Example:- ABB - Introl design or CCI - DRAG design. • In case of very high DP ( DP*100/P1 > 50%) or Noise select ABB or CCI valves. Example:- Compressor Anti - surge control valves - CCI- DRAG design.
18 VALVE SELECTION PROCESS C a r b o n s t e e l W C B C a r b o n s t e e l N A C E S t a in le s s s t e e l 3 1 6 o r 3 1 6 L S t a n d a r d M a t e r ia ls : A N S I r a t in g c la s s 1 5 0 A N S I r a t in g c la s s 3 0 0 A N S I r a tin g c la s s 6 0 0 S t a n d a r d R a t in g s : I s it s ta n d a a r d m a t e r ia l Y e s N o I s it s t a n d a r d f la n g e r a tin g Y e s N o 0 d e g . C + 4 2 0 d e g . C S t a n d a r d T e m p . R a n g g e Is te m p e r a t u r e w it h in g s t a n d a r d r a n g eY e s N o C h o k e F lo w C a v it a t io n S e v e r e S e r v ic e : N o is e a b o v e 8 5 d b A O x y g e n s e r v ic e L o w te m p e r a tu r e s e r v ic e H F s e r v ic e E t h y le n e o x id e s e r v ic e V a c u u m s e r v ic e H P s te a m s e r v ic e H y d r o g e n s e r v ic e C h lo r in e s e r v ic e I s it s e v e r s e r v ic e N o Y e s S ta n d a r d v a lv e d e s ig n a n d a p p lic a tio n . R e f D E P 3 2 .3 6 . 0 1 . 1 7 A ll S e c t io n e x c e p t 6 a n d 7 S p e c ia l v a lv e d e s ig n a n d a p p lic a t io n r e f D E P 3 2 . 3 6 .0 1 . 1 7
19 VALVE INSTALLATION IN - RPL • Based on above criteria RPL complex has following Installed quantity of valve • Fisher direct supply ( Through Bechtel ) 1400+ valves. • Fisher package supply valves 600+ • ABB UK direct supply 100+ valves. • CCI USA direct supply 25+ valves. • Note:- It does not include PP, CPP
20 VALVE INTERCHANGEABILITY • Body pressure rating and certification ( e.g. IBR ) • End connection ( Ex:- Screwed or welded flange connection ) • Valve Size and type. • Trim Size - Cv • Leakage classification • Body and trim material and certification ( e.g. NACE ) • Plug and cage characteristics. • Actuator bench setting / spring range. • Actuator action ( AFC/ AFO ) • Process temperature ( For gland packing and body - trim material )
21 Flow Path through a Control Valve - Analogy Minimum Geometrical Flow Area Streamlines Contract as Flow Approaches Restriction Vena Contracta (Minimum Flow Area)
22 Variation in Pressure and Velocity Valve Inlet Trim Exit Vena Contracta Valve OutletTrim Inlet Velocity Variation ∆PPressure Variation P1 P2
23 Pressure Recovery Valve Inlet Trim Exit Vena Contracta Valve OutletTrim Inlet ∆P Low Recovery High Recovery
24 FLASHING Flashing : The formation of vapor bubbles in liquid flow streams at vena contracta. As liquid passes through a restriction (vena contracta) in a control valve the liquid velocity increases and liquid pressure decreases. And if the pressure at this point falls to or below the vapor pressure of the liquid, vapor bubbles form in the flow stream. Flashing results if this pressure remains below vapor pressure of liquid. When a liquid flashes into vapor, there is a large increase in volume. Due to increase in volume velocity will increase and hence high velocity will erode the surface. Flashing damages can be identified by smooth polished appearance of eroded surface. Flashing damages is usually at or near seat line of the valve plug and seat ring. Vapor pressure :- The pressure at which liquid begins to vaporize.
25 FLASHING DAMAGE ( Tag no. 241FV040 )
26 FLASHING DAMAGE ( Tag no. 241FV040 )
27 CAVITATION Cavitation : The formation and subsequent collapse of vapor bubbles in liquid flow streams. As liquid passes through a restriction in a control valve the liquid velocity increases, while the liquid pressure decreases. The pressure reaches a minimum at a point called the vena contracta, and if the pressure at this point falls to or below the vapor pressure of the liquid, vapor bubbles form in the flow stream. Downstream of the vena contracta, flow area increases, velocity de-creases, and pressure increases. If this recovered pressure is sufficient to raise the pressure above the liquid vapor pressure, the vapor bubbles will collapse. The collapsing bubbles generate significant noise and vibration, and can mechanically attack pipe walls and valve components. Cavitation damages can be identified by rough and pitted surface. Cavitation damage may extend to the downstream pipeline if that is where the pressure recovery occurs. Phenomenon of Cavitation is experienced in CV and PUMPS
28 CAVITATION Valve Inlet Trim Exit Vena Contracta Valve OutletTrim Inlet ∆P P1 P2 PV PVC’
29 CAVITATION DAMAGE
30 CAVITATION CONTROLS •SYSTEM DESIGN 1. LOCATION OF VALVE 2. CASCADING •MATERIAL SELECTION HARDEN MATERIAL, LIKE 17-4 pH, 440C, 420SST HT AND 316/COLMONOY 6 / ALLOY 6
31 CAVITATION CONTROLS • ANTI - CAVITATION PRODUCTS • CCI DRAG DESIGN, UP TO 380 BAR PRESS. DROP. • FISHER CAVITROL - III DESIGN CAVITROL - III WITH 1 STAGE- UP TO 99 BAR. CAVITROL - III 2-3 STAGES- 99 TO 207 BAR. CAVITROL -4 , ABOVE 200 BAR, SIZE LIMIT 2” TO 6”. • ABB INTROL DESIGN
32 CAVITATION CONTROLS :- FISHER CAVITROL DESIGN CAVITROL - III CAVITROL - III STAGE - 2 STAGE - 3
33 CAVITATION CONTROLS :- FISHER CAVITROL DESIGN CAVITROL - 4
34 CAVITATION CONTROLS :- ABB INTROL DESIGN INTROL CAGE
35 CAVITATION CONTROLS :- CCI DRAG DESIGN CCI DRAG CAGE
36 CAVITATION CONTROLS :- CCI DRAG DESIGN
37 CAVITATION CONTROLS :- CCI DRAG DESIGN
38 CHOKED FLOW Choked flow :- Formation of vapour bubbles in the liquid flow stream cause a crowding condition at the vena contracta which tends to limit flow through the valve. If valve pressure drop is increased slightly beyond the point where bubbles begins to form, a choked flow condition is reached. With constant upstream pressure, further increase in pressure drop will not produced increased flow through the valve.
39 NOISE FUNDAMENTALS Noise :- A random mixture of sound pressure waves of various amplitudes and frequency. Which people do not like to hear. Sound Wave :- A pressure wave with a fixed frequency and amplitude traveling through a medium. Unit of Noise :- dBA ( Decibels )= 20 Log( Existing sound pressure level / 0.0002 microbars ) Source of valve noise: • Mechanical Noise :- It produces high mechanical stress - fatigue failure of vibrating part. Mechanical noise can be solved by improved design to suppress vibration by good guiding and rugged construction. • Vibration of valve components :- This is due to lateral movement of valve plug relative to guide surfaces. The sound level produce normally will have frequency less then 1500Hz and is describe as metallic rattling. • Fluid impingement upon the movable of flexible part ( Metallic chattering ) • Components resonates at its own natural frequency ( single tone 3KHz to 7KHz) • Hydrodynamic Noise :- It is due to cavitation. It is because of implosion of vapor bubbles and is relatively low.
40 NOISE FUNDAMENTALS Aerodynamic Noise :- Highest energy component at same frequency where human ear is most sensitive. Large amount of energy converted to aerodynamic noise. • High intensity noise resulting due to turbulent flow of gas, are due to high relative velocity. This can be classified as non-periodic or random noise with occurring frequency between 1 KHz to 8 KHz. • Valve pressure drop ( Main source ), • Obstruction in flow path, • Valve style , having more flow directional changes, • Degree of turbulence varies with valve style1, • Valve size.
41 PERMISSIBLE EXPOSURE DURATIONS NOISE LEVEL OSHA :- OCCUPATIONAL SAFETY AND HEALTH ACT DEFINES CRITERIA FOR PERMISSIBLE EXPOSURE DURATIONS NOISE LEVEL IN JAMNAGAR COMPLEX MAX. 85 dBA IS CONSIDERED AS A VALVE SELECTION CRITERIA. DURATION IN HOURS PER DAY SOUND LEVEL IN DBA 8 90 6 92 4 95 3 97 2 100 1-1/2 102 1 105 1/2 110 1/4 OR LESS 115
42 NOISE CONTROL • PATH TREATMENT • INSULATION OF PIPE • HEAVY WALLED PIPE • SILENCER • SOURCE TREATMENT • VALVE CAGE STYLE ( TRIM ) • WHISPER - I ( DP/P1 <= 0.65 ), Noise reduction up to 18 dBA. • WHISPER - III ( 0.6 <= DP/P1 <= 0.99 ), Noise reduction up to 30 dBA. • WHISPERFLO (NEW DESIGN), Noise reduction up to 10 dBA. • BY INLINE DIFFUSER • BY WHISPER DISK
43 NOISE CONTROL - SOURCE TREATMENT WHISPER - I DESIGN WHISPER - III DESIGN
44 NOISE CONTROL - SOURCE TREATMENT WHISPERFLO DESIGN BY FISHER
45 NOISE CONTROL - SOURCE TREATMENT WHISPER DISK AND IN LINE DIFFUSER DESIGN BY FISHER
46 NOISE CALCULATION SPL = SPL∆P + ∆SPLCG + ∆SPL∆P/P1 + ∆SPLK + ∆SPLP2 SPL = OVERALL NOISE LEVEL IN DECIBLE ( 1 METER DOWNSTREAM OF VALVE OUTLET AND 1METER FROM THE PIPE SURFACE ) SPL∆P = FUNCTION OF PRESSURE DROP ACROSS THE VALVE ( MAJOR COMPONENT ) ∆SPLCG = GAS SIZING COEFFICIENT ( MAJOR COMPONENT ) ∆SPL∆P/P1 = RATIO OF PRESSURE DIFFERENTIAL TO INLET PRESSURE ∆SPLK = CORRECTION IN DBA FOR PIPE SIZE AND SCHEDULE ∆SPLP2 = DOWNSTREAM PRESSURE SIMPLIFIED EQUATION ( WITHOUT MUCH LOSS OF ACCURACY ) : SPL = SPL∆P + ∆SPLCG
47 CONTROL VALVE GLAND PACKING
48 CONTROL VALVE GLAND PACKING Temp. Range Common use Suitablity for Oxygen /Oxidizing Service Packing material Description Stem friction Special consideration -73 to 232C Non-Radioactive Yes PTFE impregented composition Split rings of braided composition impregented with PTFE Low - All chemicals ( Except Molten alkali) Non radioactive No single PTFE V - Ring Solid rings of molded PTFE Low Vacuum Pressure / Vacuum No Double PTFE V - Ring Solid rings of molded PTFE Low -84 to 232C Vacuum, All chemicals ( Except molten alkali ) Yes Chesterton 324 Split rings of braided, preshrunk PTFE yarn impregented with PTFE; available with copper rings at top and bottom of packing box to meet UOP specification 6-14-0 for acid service. Low - -18 to 538C Water, Stem Petroleum products, Radiactive and Non-radiactive nuclear Yes but upto 371C Graphite/ Ribbon/Filament Ribbon style graphite rings and rings of braided graphite fibers with sacrificial zinc washer High Low chloride content ( less then 100ppm) chrome plated stem not necessary for high temperature service 371 to 649C High temperature oxidizing service Yes Ribbon - Style graphite Solid rings of ribbon-style graphite with sacrificial zinc washers High - -40 to 232C Required 2 to 4 micro inch RMS valve plug stem finish
49 VALVE MATERIAL Essentially material for the valve is valve assembly MOC. StandardEssentially material for the valve is valve assembly MOC. Standard material commonly used can be listed as below -material commonly used can be listed as below - Valve Body & BonnetValve Body & Bonnet - As per Process- As per Process InternalsInternals - As per Process . Commonly SS316 with or w/o- As per Process . Commonly SS316 with or w/o stellite.stellite. Valve GasketValve Gasket - Graphite, Metallic SS 316 or SS 316L- Graphite, Metallic SS 316 or SS 316L Valve PackingValve Packing - Commonly Teflon Or Graphite- Commonly Teflon Or Graphite FastenersFasteners - B7 or B8M- B7 or B8M Actuator YokeActuator Yoke - Cast Iron- Cast Iron Actuator SpringActuator Spring - Spring Steel- Spring Steel Actuator DiaphragmActuator Diaphragm - Nitrile Rubber with fabric reinforcement- Nitrile Rubber with fabric reinforcement AccessoriesAccessories - Commonly Aluminum.- Commonly Aluminum.
50 VALVE ACTUATOR Actuator - Mechanism which operates the valve by receiving the control signal. Type of Actuator Pneumatic - Spring Diaphragm Piston Cylinder Electrical - Not discussed Hydraulic- Not discussed
51 VALVE ACTUATOR
52 VALVE ACTUATOR
53 TECHNOLOGY With the advent of new technology Control Valve hasWith the advent of new technology Control Valve has undergone rapid change in terms of change in Internals,undergone rapid change in terms of change in Internals, Capacity Increase, Guiding, Leakage Class Improvement,Capacity Increase, Guiding, Leakage Class Improvement, Treatment of Noise And Cavitation And FinallyTreatment of Noise And Cavitation And Finally DIGITAL.DIGITAL. About 30 years back control valves were only availableAbout 30 years back control valves were only available with top guided or top & bottom guided design withwith top guided or top & bottom guided design with asbestos packing and practically no solution availableasbestos packing and practically no solution available for Hi Pressure drop application leading to Noise for Gasfor Hi Pressure drop application leading to Noise for Gas service Or Cavitation for Liquid Service.service Or Cavitation for Liquid Service.
54 TECHNOLOGY Now a days we are also having control valve with digital technology,Now a days we are also having control valve with digital technology, where valve positioner is digital in nature and able to provide PIDwhere valve positioner is digital in nature and able to provide PID function at the valve itself. Digital positioner can provide thefunction at the valve itself. Digital positioner can provide the following apart from acting as interface between controller and valvefollowing apart from acting as interface between controller and valve actuator -actuator - 1. Provide HART feedback.1. Provide HART feedback. 2. Can couple with Foundation Fieldbus.2. Can couple with Foundation Fieldbus. 3. Can provide valve diagnostics.3. Can provide valve diagnostics. 4. Helps in Asset Management.4. Helps in Asset Management. 5. Provide lock, soft alarms and data logging facilities.5. Provide lock, soft alarms and data logging facilities. 6. Can achieve split action, remote calibration etc.6. Can achieve split action, remote calibration etc.
55 Trouble Shooting in Control Valves. T R O U B L E S H O O T I N G T o C h e c k G la n d P a c k in g I n c r e a s e A c t u a t o r C h e c k V lv G u id in g H ig h S t e m F r ic t io n H U N T I N G ( A t a n y v lv o p e n in g ) R e d u c e d P U s e S m a lle r C v v a lv e O v e r s iz in g C h a n g e F lo w d ir . F lo w t o C lo s e flo w d ir e c t io n H U N T I N G ( N e a r t o v lv c lo s e p o s n ) I N S T A B I L I T Y C Y C L I C M O T I O N P o o r P ip in g I n c r e s e S u p p o r t O t h e r s o u r c e F in d P lu g g u id e w e a r & t e a r R e p la c e w it h n e w A t a n y v lv o p e n in g I n c r e a s e p ip e s u p p o r t T h r o t le p u m p d is c h a r g e v a lv e R e s o n a n c e o f V ib r a t io n C h a n g e p lu g p r o file C h a n g e C v v a lu e R e s o n a n c e N o is e o f v lv p lu g A t s p e c ific v lv o p e n in g V I B R A T I O N ( N O I S E ) D U L L R E S P O N S E N O T W O R K I N G A C T I O N L E A K A G E O T H E R S M A L F U N C T I O N
56 Trouble Shooting in Control Valves. T r o u b le S h o o t in g C Y C L I C M O T I O N D is s e m b le & C le a n E n la r g e g u id e r in g b le e d e r h o le P r o v id e fla s h in g p o r t U s e ja c k e t e d v lv b o d y U s e r o t a r y o r a n g le t y p e v a lv e S lu r r y / s lu d g e in v lv g u id e A c t u a t o r p is t o n r in g w e a r & t e a r C h a n g e P is t o n r in g G la n d p k g h a r d e n e d C h a n g e g la n d p k g T r a v e l N o t s m o o t h ( I n b o t h d ir ) C h a n g e d ia p h . L e a k in A c t u a t o r d ia p h . C h a n g e s t e m s e a l U s e d u s t s e a l b e llo w L e a k fr o m A c t . s t e m s e a l T r a v e l N o t s m o o t h ( I n o n e d ir ) D U L L R E S P O N S E N O T W O R K I N G A C T I O N L E A K A G E O T H E R S M A L F U N C T I O N
57 T r o u b le S h o o t in g C Y C L I C M O T I O N D U L L R E S P O N S E T r o u b le in a ir s o u r c e T r o u b le in e le c t r ic s o u r c e L e a k a g e fr o m t u b in g C h e c k c o m p . e le c s o u r c e & M a in a ir t u b in g N o s ig n a l & s u p p ly p r . T r o u b le in c o n t r o lle r C h e c k C o n t r o lle r C o n t r o l s ig le a k a g e C h e c k a ir t u b in g A c t d ia p h a ir le a k C h a n g e p a r t s P o s it io n e r a ir le a k C h a n g e b e llo w o r d ia p h N o s ig n a l p r . s u p p r . a v l A F R c o n t a m in a t io n C le a n F ilt e r P n t u b in g L e a k a g e C h e c k T u b in g ( m a in ly a ir c o n n . ) T r o u b le w it h A F R C h e c k A F R N o s u p . p r . S ig n a l p r . a v l T r o u b le in p o s n p ilo t r e la y C h e c k A c t d ia p h a ir le a k C h a n g e p a r t s P o s n O / P N il S t e m / g u id e g a llin g / ja m m in g D is a s s e m b le & c h e c k F o r e ig n p a r t ic le in v lv p o r t D is a s s e m b le & c h e c k S t e m B e n d C h a n g e p a r t s T r o u b le in A c t u a t o r C h e c k A c t S t r o k e A c t u a t o r n o t w o r k in g w it h a ir s u p . N O T W O R K I N G A C T I O N L E A K A G E O T H E R S M A L F U N C T I O N Trouble Shooting in Control Valves.
58 E n la r g e c o m p r e s s o r c a p a c it y E x c lu s iv e c o m p r e s s o r T o o m u c h a ir c o n s u m p t io n in o t h e r lin e C h e c k A F R T r o u b le in A F R D r ift o f a ir s u p p r . I n s e r t v o l t a n k & r e s t r ic t io n t o a ir s ig n a l lo o p C o n t r o l lo o p R e s is t a n c e C h e c k C o n t r o lle r T r o u b le in C o n t r o lle r H u n t in g o f S ig a ir p r . C h e c k p o s n p a r t s fr ic t io n C h e c k p o s n p ilo t r e la y P o s it io n e r lo o p h u n t in g D e c r e a s e d P H ig h e r s iz e A c t u a t o r S h ift in p lu g r e a c t io n fo r c e H u n t in g o f V lv s t e m C Y C L I C M O T I O N A C T I O N L E A K A G E O T H E R S M A L F U N C T I O N Trouble Shooting in Control Valves.
59 R e m a c h in e & L a p s e a t s u r fa c e C h a n g e s e a t & p lu g C o r r o s io n & e r o s io n o f v lv s e a t in g s u r fa c e C h a n g e s e a t & s e a t g a s k e t C h e c k s e a t d e s ig n C o r r o s io n & e r o s io n o f s e a t r in g t h r e a d o r g a s k e t T a c k w e ld d e fe c t a r e a C h a n g e v lv b o d y L e a k a g e t h r o ' in n e r v lv b o d y w a ll V a lv e C lo s e d R e d u c e d P I n c r e a s e A c t u a t o r s iz e T o o h ig h d P C h e c k fo r F o r e ig n p a r t s R e m a c h in e g a llin g p o r t io n G a llin g o n g u id e o r p o r t V a lv e n o t a b le t o c lo s e S e a t L e a k T ig h t e n p k g . n u t I n s u ffic ie n t p k g n u t t ig h t P r o v id e lu b o r c h g p k g . P k g L u b m is s in g C h a n g e p k g W e a r & t e a r o f p k g C h a n g e p a r t s o r r e m a c h in e U s e d u s t s e a l b e llo w s D a m a g e o f s t e m s u r fa c e E x a m in e p a r t M O C C h a n g e g a s k e t C o r r o s io n / e r o s io n o f s e a t g a s k e t s u r fa c e G la n d L e a k L E A K A G E C h a n g e s e a t r in g o r p lu g C o r r o s io n / e r o s io n o f p lu g o r S . r in g R a n g e a b ilit y n a r r o w e d b e c a u s e o f c o n t r o l p o s it io n c h a n g e d O T H E R S M A L F U N C T I O N Trouble Shooting in Control Valves.
60 TTHHAANNKK YYOOUU

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Control valve presentation

  • 1. 1 Reliance Petroleum Ltd. The Boss of Control Loop, Final Control Element
  • 3. 3 CONTENT - • STANDARDS APPLICABLE FOR CONTROL VALVE • WHAT IS A CONTROL VALVE ? • CONTROL VALVE LEAKAGE CLASS • CONTROL VALVE CHARACTERISTICS • CONTROL VALVE SELECTION & INTERCHANGEABILITY • FLASHING • CAVITATION • ARDUOUS SERVICE VALVE • NOISE REDUCTIONS PRACTICES • VALVE GLAND PACKING & MATERIAL OF CONSTRUCTION • CONTROL VALVE ACTUATOR TODAY’S DISCUSSION
  • 4. 4 Control Valves –Selection , Sizing and Specification • DEP 32.36.01.17- Gen July 1987 & • Basic Process control & Instrumentation Shell M114-1999 • Shell Best Practice –[Ref Process Measurement and Control Devices –Shell Canada Ltd Standard 16-1.2] SHELL REFERENCES
  • 5. 5 ANSI :- AMERICAN NATIONAL STANDARDS INSTITUTE B16.34 :- STEEL VALVES • DEFINES CRITERIA FOR VALVE WALL THICKNESS REQUIREMENTS • DEFINES PRESSURE / TEMPERATURE RATINGS • DEFINE HYDRO-TEST REQUIREMENTS Example :- A351 CF8M ( Material :- 316SST; Temp range :- -425 °F to 1500 °F) A216 WCB ( Material :- Carbon Steel; Temp range:- -20 °F to 1000 °F ) B16.37 :- HYDROSTATIC TEST PROCEDURE • DEFINES REQUIREMENT FOR HYDRO-TEST = 1.5 X MWP MWP = MAXIMUM WORKING PRESSURE B16.104 :- CONTROL VALVE SEAT LEAKAGE CLASSIFICATION • ESTABLISHES TEST PROCEDURES AND SEAT LEAKAGE CLASSES API :- AMERICAN PETROLEUM INSTITUTE SPEC 6B :- DEFINES PIPELINE VALVE SPEC 600 :- STEEL GAGE VALVES, FLANGED BUTT WELDING ENDS CONTROL VALVE STANDARDS
  • 6. 6 NACE :- NATIONAL ASSOCIATION OF CORROSION ENGINEERS NACE MR-01-75 • DEFINES SULFIDE STRESS CRACKING RESISTANCE MATERIAL • MATERIAL COMPLY TO NACE STANDARD ARE CARBON STEEL WITH HEAT TREATMENT SST 302,304,316,17-4PH ALLOY STEEL MONEY, HASTELLOY C • MATERIAL NOT SUITABLE FOR NACE ENVIRONMENT IS CAST IRON CONTROL VALVE STANDARDS
  • 7. 7 ISA :- INSTRUMENT SOCIETY OF AMERICA • DEFINES STANDARDS FOR CONTROL INDUSTRY Example :- VALVE SIZING EQUATIONS. NOISE PREDICTION TECHNIQUE CONTROL SIGNAL 3 - 15 PSIG, 6 - 30 PSIG OSHA :- OCCUPATIONAL SAFETY AND HEALTH ACT DEFINES CRITERIA FOR PERMISSIBLE DURATION FOR EXPOSURE OF NOISE LEVEL CONTROL VALVE STANDARDS
  • 8. 8 WHAT IS A CONTROL VALVE ? CONTROL VALVE This is a device used to modulate flow of process fluid in line by creating a variable pressure drop in the line . Normally the pressure drop is made with respect to the control signal received towards flow condition correction required.
  • 9. 9 TYPE OF CONTROL VALVE Also valves may be further subdivided as shown below BY SHAPE BY INTERNAL BY CHAR. BY GUIDING GLOBE PLUG EQ% TOP BUTTERFLY CAGE LINEAR CAGE ANGLE FULL BALL QUICK OPEN TOP & BOTTOM SLANT SLEEVED PARABOLIC BUSH/BEARING Y TYPE V BALL All Control valve can be divided in two category. 1. Sliding stem ( Globe valve) 2. Rotary shaft ( Quarter turn )
  • 10. 10 WHAT IS VALVE FLOW COEFFICIENT ? VALVE Cv - No. Of US gallon [ USG = 3.7 Ltrs] of water per minute passing through the valve in full open condition with 1 PSI pressure Drop across the valve at 15 deg C temp. So essentially valve Cv is capacity of valve in terms of water which helps us to identify suitable size required for any fluid in any pressure / temp. condition. VALVE Kv - Quantity of water in M3/Hr. at temperature between 5 to 40C that will flow through the valve at a specified travel with a pressure drop of 1 Bar. Kv = 0.856Cv
  • 11. 11 CONTROL VALVE LEAKAGE Control Valve Leakage -Control Valve Leakage - This is basically the fluid which passes through the valve when the valve isThis is basically the fluid which passes through the valve when the valve is fully closed. This value however should not be considered as the valve Cvfully closed. This value however should not be considered as the valve Cv at NIL Opening.at NIL Opening. So this leakage shall depend on the contact of valve plug & seat with theSo this leakage shall depend on the contact of valve plug & seat with the seating force applied for holding the plug over the seat.seating force applied for holding the plug over the seat.
  • 12. 12 CONTROL VALVE LEAKAGE ANSI/FCI 70-2 Test Medium Pressure and temperature Class II Class III Class IV Class V Water Service DP at 10 to 52deg C Port dia. Bubbles per Min. mL per Min. 1 1 0.15 1 - 1/2 2 0.30 2 3 0.45 2 - 1/2 4 0.60 3 6 0.90 4 11 1.70 6 27 4.00 8 45 6.75 Maximum Leakage 0.5% valve capacity at full travel 0.1% valve capacity at full travel 0.01% valve capacity at full travel 0.0005ml/min/psid/in. port dia Class VI Service DP or 50 PSID whichever is lower at 10 to 52deg C Water / Air Service DP or 50 PSID whichever is lower at 10 to 52deg C Air
  • 13. 13 VALVE CHARACTERISTICS Equal %Equal % - Rate of change of flow due to change of valve- Rate of change of flow due to change of valve travel is proportional to earliertravel is proportional to earlier flow.flow. LinearLinear - Rate of change of flow is same to rate of- Rate of change of flow is same to rate of change of valve travelchange of valve travel Quick OpenQuick Open - Full capacity attaining without change of- Full capacity attaining without change of travel after initial openingtravel after initial opening
  • 14. 14 1. CHARACTERISING FLOW1. CHARACTERISING FLOW • Linear CageLinear Cage • Quick Opening CageQuick Opening Cage • Equal Percentage CageEqual Percentage Cage • Modified Equal percentage flowModified Equal percentage flow 2. NOISE ABATEMENT2. NOISE ABATEMENT 3. ANTI CAVITATION3. ANTI CAVITATION TRIM AND CAGE DESIGN
  • 15. 15 CHARACTERIZING FLOW BY CAGE TYPECHARACTERIZING FLOW BY CAGE TYPE
  • 16. 16 CHARACTERIZING FLOWCHARACTERIZING FLOW Equal % Linear % Valve Travel 0 20 40 60 80 100 100 80 60 40 20 0 Cv DesignCv % Quick Opening
  • 17. 17 VALVE SELECTION PROCESS FOLLOWED IN - RPL • If valve sizing does not gives warning of cavitation, flashing or Noise level ( >85dBA) then select standard fisher trim valve. • If valve sizing gives warning of cavitation, flashing or Noise level ( >85dBA) then select arduous service trim of fisher. Example:- For cavitation select CAVITROL III stage 1 to 5 valve or CAVITROL 4 valve. For noise select WHISPER I ,III or WHISPERFLO valve trim. • If suitable fisher product is not available then select valve from ABB or CCI. Example:- ABB - Introl design or CCI - DRAG design. • In case of very high DP ( DP*100/P1 > 50%) or Noise select ABB or CCI valves. Example:- Compressor Anti - surge control valves - CCI- DRAG design.
  • 18. 18 VALVE SELECTION PROCESS C a r b o n s t e e l W C B C a r b o n s t e e l N A C E S t a in le s s s t e e l 3 1 6 o r 3 1 6 L S t a n d a r d M a t e r ia ls : A N S I r a t in g c la s s 1 5 0 A N S I r a t in g c la s s 3 0 0 A N S I r a tin g c la s s 6 0 0 S t a n d a r d R a t in g s : I s it s ta n d a a r d m a t e r ia l Y e s N o I s it s t a n d a r d f la n g e r a tin g Y e s N o 0 d e g . C + 4 2 0 d e g . C S t a n d a r d T e m p . R a n g g e Is te m p e r a t u r e w it h in g s t a n d a r d r a n g eY e s N o C h o k e F lo w C a v it a t io n S e v e r e S e r v ic e : N o is e a b o v e 8 5 d b A O x y g e n s e r v ic e L o w te m p e r a tu r e s e r v ic e H F s e r v ic e E t h y le n e o x id e s e r v ic e V a c u u m s e r v ic e H P s te a m s e r v ic e H y d r o g e n s e r v ic e C h lo r in e s e r v ic e I s it s e v e r s e r v ic e N o Y e s S ta n d a r d v a lv e d e s ig n a n d a p p lic a tio n . R e f D E P 3 2 .3 6 . 0 1 . 1 7 A ll S e c t io n e x c e p t 6 a n d 7 S p e c ia l v a lv e d e s ig n a n d a p p lic a t io n r e f D E P 3 2 . 3 6 .0 1 . 1 7
  • 19. 19 VALVE INSTALLATION IN - RPL • Based on above criteria RPL complex has following Installed quantity of valve • Fisher direct supply ( Through Bechtel ) 1400+ valves. • Fisher package supply valves 600+ • ABB UK direct supply 100+ valves. • CCI USA direct supply 25+ valves. • Note:- It does not include PP, CPP
  • 20. 20 VALVE INTERCHANGEABILITY • Body pressure rating and certification ( e.g. IBR ) • End connection ( Ex:- Screwed or welded flange connection ) • Valve Size and type. • Trim Size - Cv • Leakage classification • Body and trim material and certification ( e.g. NACE ) • Plug and cage characteristics. • Actuator bench setting / spring range. • Actuator action ( AFC/ AFO ) • Process temperature ( For gland packing and body - trim material )
  • 21. 21 Flow Path through a Control Valve - Analogy Minimum Geometrical Flow Area Streamlines Contract as Flow Approaches Restriction Vena Contracta (Minimum Flow Area)
  • 22. 22 Variation in Pressure and Velocity Valve Inlet Trim Exit Vena Contracta Valve OutletTrim Inlet Velocity Variation ∆PPressure Variation P1 P2
  • 24. 24 FLASHING Flashing : The formation of vapor bubbles in liquid flow streams at vena contracta. As liquid passes through a restriction (vena contracta) in a control valve the liquid velocity increases and liquid pressure decreases. And if the pressure at this point falls to or below the vapor pressure of the liquid, vapor bubbles form in the flow stream. Flashing results if this pressure remains below vapor pressure of liquid. When a liquid flashes into vapor, there is a large increase in volume. Due to increase in volume velocity will increase and hence high velocity will erode the surface. Flashing damages can be identified by smooth polished appearance of eroded surface. Flashing damages is usually at or near seat line of the valve plug and seat ring. Vapor pressure :- The pressure at which liquid begins to vaporize.
  • 25. 25 FLASHING DAMAGE ( Tag no. 241FV040 )
  • 26. 26 FLASHING DAMAGE ( Tag no. 241FV040 )
  • 27. 27 CAVITATION Cavitation : The formation and subsequent collapse of vapor bubbles in liquid flow streams. As liquid passes through a restriction in a control valve the liquid velocity increases, while the liquid pressure decreases. The pressure reaches a minimum at a point called the vena contracta, and if the pressure at this point falls to or below the vapor pressure of the liquid, vapor bubbles form in the flow stream. Downstream of the vena contracta, flow area increases, velocity de-creases, and pressure increases. If this recovered pressure is sufficient to raise the pressure above the liquid vapor pressure, the vapor bubbles will collapse. The collapsing bubbles generate significant noise and vibration, and can mechanically attack pipe walls and valve components. Cavitation damages can be identified by rough and pitted surface. Cavitation damage may extend to the downstream pipeline if that is where the pressure recovery occurs. Phenomenon of Cavitation is experienced in CV and PUMPS
  • 30. 30 CAVITATION CONTROLS •SYSTEM DESIGN 1. LOCATION OF VALVE 2. CASCADING •MATERIAL SELECTION HARDEN MATERIAL, LIKE 17-4 pH, 440C, 420SST HT AND 316/COLMONOY 6 / ALLOY 6
  • 31. 31 CAVITATION CONTROLS • ANTI - CAVITATION PRODUCTS • CCI DRAG DESIGN, UP TO 380 BAR PRESS. DROP. • FISHER CAVITROL - III DESIGN CAVITROL - III WITH 1 STAGE- UP TO 99 BAR. CAVITROL - III 2-3 STAGES- 99 TO 207 BAR. CAVITROL -4 , ABOVE 200 BAR, SIZE LIMIT 2” TO 6”. • ABB INTROL DESIGN
  • 32. 32 CAVITATION CONTROLS :- FISHER CAVITROL DESIGN CAVITROL - III CAVITROL - III STAGE - 2 STAGE - 3
  • 33. 33 CAVITATION CONTROLS :- FISHER CAVITROL DESIGN CAVITROL - 4
  • 34. 34 CAVITATION CONTROLS :- ABB INTROL DESIGN INTROL CAGE
  • 35. 35 CAVITATION CONTROLS :- CCI DRAG DESIGN CCI DRAG CAGE
  • 36. 36 CAVITATION CONTROLS :- CCI DRAG DESIGN
  • 37. 37 CAVITATION CONTROLS :- CCI DRAG DESIGN
  • 38. 38 CHOKED FLOW Choked flow :- Formation of vapour bubbles in the liquid flow stream cause a crowding condition at the vena contracta which tends to limit flow through the valve. If valve pressure drop is increased slightly beyond the point where bubbles begins to form, a choked flow condition is reached. With constant upstream pressure, further increase in pressure drop will not produced increased flow through the valve.
  • 39. 39 NOISE FUNDAMENTALS Noise :- A random mixture of sound pressure waves of various amplitudes and frequency. Which people do not like to hear. Sound Wave :- A pressure wave with a fixed frequency and amplitude traveling through a medium. Unit of Noise :- dBA ( Decibels )= 20 Log( Existing sound pressure level / 0.0002 microbars ) Source of valve noise: • Mechanical Noise :- It produces high mechanical stress - fatigue failure of vibrating part. Mechanical noise can be solved by improved design to suppress vibration by good guiding and rugged construction. • Vibration of valve components :- This is due to lateral movement of valve plug relative to guide surfaces. The sound level produce normally will have frequency less then 1500Hz and is describe as metallic rattling. • Fluid impingement upon the movable of flexible part ( Metallic chattering ) • Components resonates at its own natural frequency ( single tone 3KHz to 7KHz) • Hydrodynamic Noise :- It is due to cavitation. It is because of implosion of vapor bubbles and is relatively low.
  • 40. 40 NOISE FUNDAMENTALS Aerodynamic Noise :- Highest energy component at same frequency where human ear is most sensitive. Large amount of energy converted to aerodynamic noise. • High intensity noise resulting due to turbulent flow of gas, are due to high relative velocity. This can be classified as non-periodic or random noise with occurring frequency between 1 KHz to 8 KHz. • Valve pressure drop ( Main source ), • Obstruction in flow path, • Valve style , having more flow directional changes, • Degree of turbulence varies with valve style1, • Valve size.
  • 41. 41 PERMISSIBLE EXPOSURE DURATIONS NOISE LEVEL OSHA :- OCCUPATIONAL SAFETY AND HEALTH ACT DEFINES CRITERIA FOR PERMISSIBLE EXPOSURE DURATIONS NOISE LEVEL IN JAMNAGAR COMPLEX MAX. 85 dBA IS CONSIDERED AS A VALVE SELECTION CRITERIA. DURATION IN HOURS PER DAY SOUND LEVEL IN DBA 8 90 6 92 4 95 3 97 2 100 1-1/2 102 1 105 1/2 110 1/4 OR LESS 115
  • 42. 42 NOISE CONTROL • PATH TREATMENT • INSULATION OF PIPE • HEAVY WALLED PIPE • SILENCER • SOURCE TREATMENT • VALVE CAGE STYLE ( TRIM ) • WHISPER - I ( DP/P1 <= 0.65 ), Noise reduction up to 18 dBA. • WHISPER - III ( 0.6 <= DP/P1 <= 0.99 ), Noise reduction up to 30 dBA. • WHISPERFLO (NEW DESIGN), Noise reduction up to 10 dBA. • BY INLINE DIFFUSER • BY WHISPER DISK
  • 43. 43 NOISE CONTROL - SOURCE TREATMENT WHISPER - I DESIGN WHISPER - III DESIGN
  • 44. 44 NOISE CONTROL - SOURCE TREATMENT WHISPERFLO DESIGN BY FISHER
  • 45. 45 NOISE CONTROL - SOURCE TREATMENT WHISPER DISK AND IN LINE DIFFUSER DESIGN BY FISHER
  • 46. 46 NOISE CALCULATION SPL = SPL∆P + ∆SPLCG + ∆SPL∆P/P1 + ∆SPLK + ∆SPLP2 SPL = OVERALL NOISE LEVEL IN DECIBLE ( 1 METER DOWNSTREAM OF VALVE OUTLET AND 1METER FROM THE PIPE SURFACE ) SPL∆P = FUNCTION OF PRESSURE DROP ACROSS THE VALVE ( MAJOR COMPONENT ) ∆SPLCG = GAS SIZING COEFFICIENT ( MAJOR COMPONENT ) ∆SPL∆P/P1 = RATIO OF PRESSURE DIFFERENTIAL TO INLET PRESSURE ∆SPLK = CORRECTION IN DBA FOR PIPE SIZE AND SCHEDULE ∆SPLP2 = DOWNSTREAM PRESSURE SIMPLIFIED EQUATION ( WITHOUT MUCH LOSS OF ACCURACY ) : SPL = SPL∆P + ∆SPLCG
  • 48. 48 CONTROL VALVE GLAND PACKING Temp. Range Common use Suitablity for Oxygen /Oxidizing Service Packing material Description Stem friction Special consideration -73 to 232C Non-Radioactive Yes PTFE impregented composition Split rings of braided composition impregented with PTFE Low - All chemicals ( Except Molten alkali) Non radioactive No single PTFE V - Ring Solid rings of molded PTFE Low Vacuum Pressure / Vacuum No Double PTFE V - Ring Solid rings of molded PTFE Low -84 to 232C Vacuum, All chemicals ( Except molten alkali ) Yes Chesterton 324 Split rings of braided, preshrunk PTFE yarn impregented with PTFE; available with copper rings at top and bottom of packing box to meet UOP specification 6-14-0 for acid service. Low - -18 to 538C Water, Stem Petroleum products, Radiactive and Non-radiactive nuclear Yes but upto 371C Graphite/ Ribbon/Filament Ribbon style graphite rings and rings of braided graphite fibers with sacrificial zinc washer High Low chloride content ( less then 100ppm) chrome plated stem not necessary for high temperature service 371 to 649C High temperature oxidizing service Yes Ribbon - Style graphite Solid rings of ribbon-style graphite with sacrificial zinc washers High - -40 to 232C Required 2 to 4 micro inch RMS valve plug stem finish
  • 49. 49 VALVE MATERIAL Essentially material for the valve is valve assembly MOC. StandardEssentially material for the valve is valve assembly MOC. Standard material commonly used can be listed as below -material commonly used can be listed as below - Valve Body & BonnetValve Body & Bonnet - As per Process- As per Process InternalsInternals - As per Process . Commonly SS316 with or w/o- As per Process . Commonly SS316 with or w/o stellite.stellite. Valve GasketValve Gasket - Graphite, Metallic SS 316 or SS 316L- Graphite, Metallic SS 316 or SS 316L Valve PackingValve Packing - Commonly Teflon Or Graphite- Commonly Teflon Or Graphite FastenersFasteners - B7 or B8M- B7 or B8M Actuator YokeActuator Yoke - Cast Iron- Cast Iron Actuator SpringActuator Spring - Spring Steel- Spring Steel Actuator DiaphragmActuator Diaphragm - Nitrile Rubber with fabric reinforcement- Nitrile Rubber with fabric reinforcement AccessoriesAccessories - Commonly Aluminum.- Commonly Aluminum.
  • 50. 50 VALVE ACTUATOR Actuator - Mechanism which operates the valve by receiving the control signal. Type of Actuator Pneumatic - Spring Diaphragm Piston Cylinder Electrical - Not discussed Hydraulic- Not discussed
  • 53. 53 TECHNOLOGY With the advent of new technology Control Valve hasWith the advent of new technology Control Valve has undergone rapid change in terms of change in Internals,undergone rapid change in terms of change in Internals, Capacity Increase, Guiding, Leakage Class Improvement,Capacity Increase, Guiding, Leakage Class Improvement, Treatment of Noise And Cavitation And FinallyTreatment of Noise And Cavitation And Finally DIGITAL.DIGITAL. About 30 years back control valves were only availableAbout 30 years back control valves were only available with top guided or top & bottom guided design withwith top guided or top & bottom guided design with asbestos packing and practically no solution availableasbestos packing and practically no solution available for Hi Pressure drop application leading to Noise for Gasfor Hi Pressure drop application leading to Noise for Gas service Or Cavitation for Liquid Service.service Or Cavitation for Liquid Service.
  • 54. 54 TECHNOLOGY Now a days we are also having control valve with digital technology,Now a days we are also having control valve with digital technology, where valve positioner is digital in nature and able to provide PIDwhere valve positioner is digital in nature and able to provide PID function at the valve itself. Digital positioner can provide thefunction at the valve itself. Digital positioner can provide the following apart from acting as interface between controller and valvefollowing apart from acting as interface between controller and valve actuator -actuator - 1. Provide HART feedback.1. Provide HART feedback. 2. Can couple with Foundation Fieldbus.2. Can couple with Foundation Fieldbus. 3. Can provide valve diagnostics.3. Can provide valve diagnostics. 4. Helps in Asset Management.4. Helps in Asset Management. 5. Provide lock, soft alarms and data logging facilities.5. Provide lock, soft alarms and data logging facilities. 6. Can achieve split action, remote calibration etc.6. Can achieve split action, remote calibration etc.
  • 55. 55 Trouble Shooting in Control Valves. T R O U B L E S H O O T I N G T o C h e c k G la n d P a c k in g I n c r e a s e A c t u a t o r C h e c k V lv G u id in g H ig h S t e m F r ic t io n H U N T I N G ( A t a n y v lv o p e n in g ) R e d u c e d P U s e S m a lle r C v v a lv e O v e r s iz in g C h a n g e F lo w d ir . F lo w t o C lo s e flo w d ir e c t io n H U N T I N G ( N e a r t o v lv c lo s e p o s n ) I N S T A B I L I T Y C Y C L I C M O T I O N P o o r P ip in g I n c r e s e S u p p o r t O t h e r s o u r c e F in d P lu g g u id e w e a r & t e a r R e p la c e w it h n e w A t a n y v lv o p e n in g I n c r e a s e p ip e s u p p o r t T h r o t le p u m p d is c h a r g e v a lv e R e s o n a n c e o f V ib r a t io n C h a n g e p lu g p r o file C h a n g e C v v a lu e R e s o n a n c e N o is e o f v lv p lu g A t s p e c ific v lv o p e n in g V I B R A T I O N ( N O I S E ) D U L L R E S P O N S E N O T W O R K I N G A C T I O N L E A K A G E O T H E R S M A L F U N C T I O N
  • 56. 56 Trouble Shooting in Control Valves. T r o u b le S h o o t in g C Y C L I C M O T I O N D is s e m b le & C le a n E n la r g e g u id e r in g b le e d e r h o le P r o v id e fla s h in g p o r t U s e ja c k e t e d v lv b o d y U s e r o t a r y o r a n g le t y p e v a lv e S lu r r y / s lu d g e in v lv g u id e A c t u a t o r p is t o n r in g w e a r & t e a r C h a n g e P is t o n r in g G la n d p k g h a r d e n e d C h a n g e g la n d p k g T r a v e l N o t s m o o t h ( I n b o t h d ir ) C h a n g e d ia p h . L e a k in A c t u a t o r d ia p h . C h a n g e s t e m s e a l U s e d u s t s e a l b e llo w L e a k fr o m A c t . s t e m s e a l T r a v e l N o t s m o o t h ( I n o n e d ir ) D U L L R E S P O N S E N O T W O R K I N G A C T I O N L E A K A G E O T H E R S M A L F U N C T I O N
  • 57. 57 T r o u b le S h o o t in g C Y C L I C M O T I O N D U L L R E S P O N S E T r o u b le in a ir s o u r c e T r o u b le in e le c t r ic s o u r c e L e a k a g e fr o m t u b in g C h e c k c o m p . e le c s o u r c e & M a in a ir t u b in g N o s ig n a l & s u p p ly p r . T r o u b le in c o n t r o lle r C h e c k C o n t r o lle r C o n t r o l s ig le a k a g e C h e c k a ir t u b in g A c t d ia p h a ir le a k C h a n g e p a r t s P o s it io n e r a ir le a k C h a n g e b e llo w o r d ia p h N o s ig n a l p r . s u p p r . a v l A F R c o n t a m in a t io n C le a n F ilt e r P n t u b in g L e a k a g e C h e c k T u b in g ( m a in ly a ir c o n n . ) T r o u b le w it h A F R C h e c k A F R N o s u p . p r . S ig n a l p r . a v l T r o u b le in p o s n p ilo t r e la y C h e c k A c t d ia p h a ir le a k C h a n g e p a r t s P o s n O / P N il S t e m / g u id e g a llin g / ja m m in g D is a s s e m b le & c h e c k F o r e ig n p a r t ic le in v lv p o r t D is a s s e m b le & c h e c k S t e m B e n d C h a n g e p a r t s T r o u b le in A c t u a t o r C h e c k A c t S t r o k e A c t u a t o r n o t w o r k in g w it h a ir s u p . N O T W O R K I N G A C T I O N L E A K A G E O T H E R S M A L F U N C T I O N Trouble Shooting in Control Valves.
  • 58. 58 E n la r g e c o m p r e s s o r c a p a c it y E x c lu s iv e c o m p r e s s o r T o o m u c h a ir c o n s u m p t io n in o t h e r lin e C h e c k A F R T r o u b le in A F R D r ift o f a ir s u p p r . I n s e r t v o l t a n k & r e s t r ic t io n t o a ir s ig n a l lo o p C o n t r o l lo o p R e s is t a n c e C h e c k C o n t r o lle r T r o u b le in C o n t r o lle r H u n t in g o f S ig a ir p r . C h e c k p o s n p a r t s fr ic t io n C h e c k p o s n p ilo t r e la y P o s it io n e r lo o p h u n t in g D e c r e a s e d P H ig h e r s iz e A c t u a t o r S h ift in p lu g r e a c t io n fo r c e H u n t in g o f V lv s t e m C Y C L I C M O T I O N A C T I O N L E A K A G E O T H E R S M A L F U N C T I O N Trouble Shooting in Control Valves.
  • 59. 59 R e m a c h in e & L a p s e a t s u r fa c e C h a n g e s e a t & p lu g C o r r o s io n & e r o s io n o f v lv s e a t in g s u r fa c e C h a n g e s e a t & s e a t g a s k e t C h e c k s e a t d e s ig n C o r r o s io n & e r o s io n o f s e a t r in g t h r e a d o r g a s k e t T a c k w e ld d e fe c t a r e a C h a n g e v lv b o d y L e a k a g e t h r o ' in n e r v lv b o d y w a ll V a lv e C lo s e d R e d u c e d P I n c r e a s e A c t u a t o r s iz e T o o h ig h d P C h e c k fo r F o r e ig n p a r t s R e m a c h in e g a llin g p o r t io n G a llin g o n g u id e o r p o r t V a lv e n o t a b le t o c lo s e S e a t L e a k T ig h t e n p k g . n u t I n s u ffic ie n t p k g n u t t ig h t P r o v id e lu b o r c h g p k g . P k g L u b m is s in g C h a n g e p k g W e a r & t e a r o f p k g C h a n g e p a r t s o r r e m a c h in e U s e d u s t s e a l b e llo w s D a m a g e o f s t e m s u r fa c e E x a m in e p a r t M O C C h a n g e g a s k e t C o r r o s io n / e r o s io n o f s e a t g a s k e t s u r fa c e G la n d L e a k L E A K A G E C h a n g e s e a t r in g o r p lu g C o r r o s io n / e r o s io n o f p lu g o r S . r in g R a n g e a b ilit y n a r r o w e d b e c a u s e o f c o n t r o l p o s it io n c h a n g e d O T H E R S M A L F U N C T I O N Trouble Shooting in Control Valves.