EKC 493 Chemical Engineering Laboratory III

PC 3
CONTROL VALVE CHARACTERSISTICS
WCV 911

OBJECTIVES
To operate and demonstrate the operation of control valve plant
To sketch the major equipment, instrumentation, control infrastructure and controller
To classify the types of control valves
To calculate the Cv of three control valve at various valve opening
To combine information for experiment from multiple sources

INTRODUCTION
Pneumatic control valve is the most important final control element in the chemical process
industry. Depending on the relationship between percentage flow and percentage flow control,
valves can have different characteristics. Pneumatic control valves are air operated and hence a
current-air transducer is required to convert the 4-20mA controller output.

EXPERIMENT A
AIM :
a) To determine and study the installed characteristics of three control valves that are installed in
their respective piping system where more pressure drop is expected at the control valve than
at the rest of the pipeline system.
b) To calculate the Cv of three control valves at various Valve Openings.

CONTROL VALVES : FCVL, FCVE, FCVQ

SPECIAL REMARKS : Operate the smaller capacity pump PS through the three control valves
one at a time, with its pipeline and manual valves fully opened for minimum pressure drop at the
pipeline. FIC remains in Manual (M) mode. The control valves Positioners (PP) are connected.

KEY PARAMETERS : Flowrate (F), Valve Opening (Z or m), valve Pressure Drop (DPv),
Pump discharge pressure (PGS). The input parameter is the valve input signal i.e. the control
output MV from FIC in Manual (M) mode.

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PROCEDURE

1. to 10. Please do “START-UP CHECK LIST”. ( Please discuss with the technician involve
for startup check list).

11. This Experiment A requires only pump PS to be operated. Pump PB should be OFF.
Its manual discharge valve MVB must be fully shut.
12. Do a quick check of the following.
a) All the pumps suction valves are fully opened.

b) Tanks T1 and T2 are filled with water almost up to the overflow pipe.

c) The instrument air supply is connected and the air regulator (IAS) pressure is

appropriately set (maximum 2 bar).

d) Switch the panel to Scada.

e) The main power supply is ON and the Controller FIC and digital FDPZR have
lit up. FIC is in Manual ( M) mode with its MV = 100% throughout this
EXPERIMENT A.
13. Pump PS with the control valve FCVL at pipeline PLL: PS/FCVL/PLL, Position 1.

a) Open fully the following manual valves: BVS, MVS, MVL1, MVL2.

b) Shut fully the following manual valves: MVB, MVE1, MVQ1, BVL.

c) For operation of FCVL, turn the Selector Switch SS1 to Position 1.

Note: Please see Table: 1.

d) Controller FIC must be in Manual (M) mode with its MV = 100%. Make sure the
chart drive of the digital FDPZR is ON.

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TABLE 1 : OPERATION
A Select Control valve i) Select the Selector Switch ii) Set up the Manual Valves
below, either FCVL or SS1 Positions to either 1, 2 as follows:
FCVE or FCVQ or 3
Either FCVL/PLL 1 Open MVL1, MVL2. Shut
MVE1, MVQ1, BVL
or FCVE/PLE 2 Open MVE1, MVE2. Shut
MVL1, MVQ1, BVE
or FCVQ/PLQ 3 Open MVQ1, MVQ2. Shut
MVL1, MVE1, BVQ
B Use the Controller FIC to manually regulate the selected Control Valve
Check that FIC is in Manual (M) mode. Start with MV at 100%.
C Select pump to operate, either PS or PB
• To operate PS: Open MVS, Shut MVB. Shut BVS fully after PS start up.
Note Fmax* :
• To operate PB : Open MVB, Shut MVS. Shut BVB fully after PB start-up.
Adjust MVB for similar Fmax* as in operating PB.
D PGS, PGB for pump discharge pressure
Pump not operating displays 0 discharge pressure

Start pump PS and verify its flow at the discharge of pipeline PLL into tank T2.
Shut fully the pump by pass manual valve BVS for maximum available flow
-

through the control valve FCVL and the pipeline PLL using the smaller pump PS.

NOTE THIS MAXIMUM AVAILABLE FLOWRATE Fmax (L)* FOR FCVL AT

THE DIGITAL FDPZR. Please note down Fmax(L)*. Fmax (L)* will be required
later for Experiment B

f) Note the following readings at the digital FDPZR and the pressure gauge PGS.
Key in all the data sheet (See Table 2). Consider 100% of MV as Fmax.

g) Repeat (f) but this time, adjust the manual output of FIC by 10 to 20% at a time,
so that its MV is in decreasing (i.e. 100% to 0.0%) and then in increasing MV (i.e.
0.0 to 100%).

h) Stop pump PS and proceed to test the next control valve. Repeat the experiment for the
FCVE and FCVQ.

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Table 2: Data sheet for experiment

Adjust Flowrate (F) % Valve Opening (Z Valve pressure drop Pump

FIC or m) % (DPv) % discharge Calculate the following ratio
Manual pressure,
Output, PGS
MV % psig
(F/Fmax) DPv/PGS Cv/Cvmax
* 100%
%

100.0 Fmax(L/E/Q)*
….
….
… 0.0

0.0 …
….
….
100.0 Fmax(L/E/Q)*

* There should be three tables for control valves FVCL, FCVE and FCVQ respectively
*******************************************************************

EXPERIMENT B

The aim of the experiment is similar to the Experiment A with the same control valves and key
parameters but with the big pump (PB).

SPECIAL REMARKS : Operate the larger capacity pump PB through the three control valves
one at a time, with the manual valve MVB manually regulated (i.e. shut slightly) so that the
maximum available flowrate is the same as in Experiment A. The closing of the manual valve
MVB is used to increase the pressure drop distribution at the pipeline i.e. increase DPL.
FIC remains in Manual (M) mode. The control valves Positioners (PP) are connected (The procedure is
highlighted in Table ).
The procedure (1 – 13) is similar to the Experiment A with special note on the respective valves.

Control Valve FCVL:

NOTE THIS MAXIMUM AVAILABLE FLOWRATE IS HIGHER THAN IN THE PREVIOUS
EXPERIMENT A (13e) WHICH USES SMALLER PUMP PS TO PRODUCE Fmax(L)* FOR
FCVL. PLEASE REFER TO EXPERIMENT A, PROCEDURE 13(e) AND ( f), AND NOTE
THE MAXIMUM AVAILABLE FLOWRATE (Fmax(L)* for FCVL) OPERATING PUMP PS
(WITH MV = 100% AND BVS FULLY SHUT).

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NOW ADJUST THE MANUAL VALVE MVB SO THAT THE MAXIMUM AVAILABLE
FLOWRATE (Fmax(L)*) HERE OPERATING PUMP PB (WITH MV = 100% AND BVB
FULLY SHUT) IS ALMOST THE SAME AS IN EXPERIMENT A, 13(e) AND (f) i.e.
Fmax(L)* FOR FCVL USING PUMP PS. ONCE MVB IS ADJUSTED HERE, IT MUST NOT
BE READJUSTED AGAIN THROUGHOUT THIS EXPERIMENT. THIS NOTES WERE
ALSO APPLIED FOR THE FCVE AND FCVQ.

Tabke 3: Data sheet for experiment B

Adjust Flowrate (F) % Valve Opening (Z Valve pressure drop Pump

FIC or m) % (DPv) % discharge Calculate the following ratio
Manual pressure,
Output, PGS
MV % psig
(F/Fmax) DPv/PGS Cv/Cvmax
* 100%
%

100.0 Fmax(L/E/Q)*
….
….
… 0.0

0.0 …
….
….
100.0 Fmax(L/E/Q)*

* There should be three tables for control valves FVCL, FCVE and FCVQ respectively
*******************************************************************

EXPERIMENT C

AIM : To test the effect of different control valve characteristics on PID Flow loop tuning.

CONTROL VALVES : The PID Flow loop consists of

a. FT-FIC-FCY-PP/FCVL

b. FT-FIC-FCY-PP/FCVE

c. FT-FIC-FCY-PP/FCVQ

SPECIAL REMARKS : Operate one Flow loop i.e. one pipeline at a time in Auto (A) mode at
three different flow setpoint (SV) using pump PS. Then use pump PB but at the same maximum
flowrate as using pump PS at its maximum flowrate.
KEY VARIABLE : The controlled variable is the volumetric flowrate measured by the
Electromagnetic flowmeter FT.

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PROCEDURES

1. Do a quick check of the following.

a) All the pump suction valves are fully opened.
b) Tanks T1 and T2 are filled with water almost up to the overflow pipe.
c) The Instrument air supply is connected and the air regulator (IAS) pressure is
appropriately set.
d) The main power supply is ON and the Controller FIC and Recorder FDPZR have
lit up.
• FIC is in Manual (M) mode with its MV = 100%.
• The setpoint SV is at 15 USGPM.

2. Experiment C1 - Flow Loop Tuning Tests with FCVL

a)
• Change the Selector Switch to Position 1, to select control valve FCVL for operation.
• Switch FIC to Manual (M) mode and with its MV=100%, open FCVL fully
• Shut fully manual valves MVE1, MVQ1, BVL but open fully MVL1 and MVL2.

b)
• To operate only pump PS, shut fully manual valve MVB but open fully MVS and BVS
(the manual by-pass valve of pump PS).
• Start pump PS from the panel front pushbutton and verify its flow at the discharge of
pipeline PLL into tank T2.
• Shut BVS fully for maximum available flowrate through FCVL/PLL. Since FCVL is fully
opened (MV at FIC is 100%), note this maximum flowrate Fmax (L)* through FCVL from
pump PS.

c) At SV = 15 USGPM, Test 2L1 (FCVL/PS)

Check that the Flow Controller FIC is set as follows: PB1 = 100%; TI1 = 5 secs; TD1 =
0 sec Setpoint SV = 15 USGPM The PID values are set at the PID1 page/panel at FIC.

d) Check that the chart drive of the Recorder FDPZR is running.

e) Switch FIC to Auto (A) mode and observe the flowrate response (Red pen) patiently
until it remains steady or it continues to oscillate for 3 cycles. Note the valve opening (Z
or m) value from the recorder (Green pen). Is the response TOO SLUGGISH OR TOO
OSCILLATORY, that RETUNING is required?

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f) If necessary apply a load step disturbance test as follows: Switch FIC to Manual (M)
mode, step increase or decrease its MV by about 20%, then quickly switch FIC back to
Auto (A) mode and observe similarly.

h) At SV = 10 USGPM, Test 2L2 (FCVL/PS) With FIC still in Auto (A) mode, step change its
setpoint SV to 10 USGPM and observe the flow response (Red pen) similarly. If necessary,
apply a load step test as in the previous (f). This is Test 2L2. Note also the valve opening (Z or
m) at the recorder (Green pen). Mark on the Recorder Red trend “FCVL/PS” and “10/100/5/0”
(denoting the SV/PB/TI/TD values).

i) At SV = 5 USGPM, Test 2L3 (FCVL/PS) With FIC still in Auto (A) mode, step change its
setpoint SV to 5 USGPM and observe the flow response (Red pen) similarly. If necessary,
apply a load step test as in the previous (f). This is Test 2L3. Mark on the Recorder Red trend
“FCVL/PS” and “5/100/5/0” (denoting the SV/PB/TI/TD values). The chart responses are part
of the results of this Experiment C. Note also the valve opening (Z or m) at the recorder (Green
pen).
THE NEXT THREE TESTS WILL BE REPEATED USING PUMP PB WITH FCVL
INSTEAD OF PUMP PS.
• Stop pump PS. Shut fully MVS.
• Open fully MVB, BVB.
• Switch FIC to Manual (M) mode and with its MV= 100%, open FCVL fully.
• Start pump PB and verify its discharge into tank T2 from pipeline PLL.
• Shut BVB fully for maximum available flowrate through FCVL/PLL.
• Manually regulate MVB until this maximum flowrate is equal to Fmax(L)* from the earlier
Procedure 13(b) For the rest of Procedures 13 (j), (k), (l), do not readjust MVB again.

j) At SV = 5 USGPM, Test 2L4 (FCVL/PB) With FIC in Auto ( A) mode, observe the flow
response (Red pen) similarly. If further test at SV = 5 USGPM is necessary, apply a load step
test as in 13(f), by switching FIC to Manual (M) mode, step changing MV by about 20%, and
then switching FIC back to Auto (A) mode. Observe similarly. This is Test 2L4. Mark on the
Recorder Red trend “FCVL/PB” and “5/100/5/0”.

14. Experiment C2 - Flow Loop Tuning Tests with FCVE

REPEAT THE SIMILAR PROCEDURE FOR EXPERIMENT C1 BUT ONLY WITH THE
SELECTOR SWITCH AT POSITION 2.

15. Experiment C3 - Flow Loop Tuning Tests with FCVQ

REPEAT THE SIMILAR PROCEDURE FOR EXPERIMENT C1 BUT ONLY WITH THE
SELECTOR SWITCH AT POSITION 3.

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Figure 1: PID Diagram

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