Adca Training

Part 5

This presentation is only a guideline, that can only be completed by a trained personnel.
(This document’s total or partial use and/or reproduction is only allowed if the reference to the source is kept)
 Part 5
▪ Control Valves
▪ Components of Control Valves
▪ Humidification
▪ Modern plants demand accurate distribution and control of fluids, either
they are liquid or gas.

▪ Among several elements required for an effective control system –

instruments, probes, controllers, etc- control valves play a very important
role.

▪ In spite of their relevance as control element in an automatic control

loop, control valves are mostly “misunderstood” and even disregarded.

▪ Thus, control valves correct selection and sizing is capital to the perfect
behaviour of control loop.
▪ Cavitation – With liquids service, the two stage process of vaporization
and condensation. When the pressure falls (See “Vena Contracta”)
bellow the fluid vapour pressure, vaporization occurs. The vapour
bubbles created proceed downstream and as far as the fluid pressure
recovers, the vapour bubbles collapse (implode), which can cause
mechanical damage to the valves and piping.

▪ Flashing – When the liquid vapour pressure downstream of a control

valve is less than the upstream vapour pressure, part of the liquid
changes to a vapour and it will remain as a vapour, unless the
downstream pressure recovers. If this happens cavitation will occur.
Flashing can also causes critical flow.
▪ Critical (choked) Flow – When at a fixed upstream pressure the flow
cannot be increased by lowering the downstream pressure. This
conditions happen with gases (steam, air, etc) or liquids (in the flashing
or cavitation condition).
With steam and gases, if the pressure drop at “vena contracta” is
sufficiently high, the velocity in the flow stream will reach the velocity of
sound – pressure drop across the valve equal or more than one half of
absolute inlet pressure.

▪ Rangeability – The ratio of the maximum to minimum controllable flow.

▪ Flow Coefficient (Kv) - Represents the quantity of water , expressed in

cubic meters (m3) at 15ºC, that flows through the valve with a pressure
drop of 1 bar , in one hour period.
Fluid pressure

Outlet pressure
Vapour pressure
Flashing

Lowest pressure
(“vena contracta”)

Distance along flow stream

 Corrective signal Feedback signal

Actuator
Controller
Measuring
Element

Positioner
Temperature
Fluid Pressure
Level
Density
Humidity
Valve Body …

▪ The signal transmitted to the controller is compared with the desired set
point and if necessary will re-adjust the control valve through a corrective
signal.
Self Regulating Valves Automatic Control Valves
(Globe Type)

Three Way Two Way Plug Two Way Cage

(Single Seat) (Single Seat)

Self Acting Temperature Mixing Diverting Unbalanced Balanced

Control Valves
▪ The expansion of the temperature
sensitive fluid in the sensor is Direct action
transmitted through capillary tubing to Heating
the valve actuator. Here it is turned TR 25
into linear thrust to actuate the valve.
When the temperature falls, the fluid
contracts and a return spring moves
the valve in the opposite direction.

▪ The sensor incorporates an

overload bellows to take up any
excess pressure which may develop Reverse action
by any temperature over-run. Cooling

▪ Temperature over-run can therefore

be tolerated within certain limits
without rupture of the system.
 Electric Pneumatic
Adcatrol
Actuator

EL Series Adcatrol PA Series

Valve Body

Two Way Three Way

V25 V253

Adcatrol Adcatrol
EV25 EV253 PV25 PV253
PV 253G PV 25I PV 25G

EV 16G
PWV40I
 Connections:
ISO
ASME BPE
DIN
SMS
BS
... Variants
PV 922 PV 926 PV 928
▪ Pharma, food, chemical and cosmetic industries, require polished valves to 0,5 microns Ra
▪ The Adcapure includes all types of connections such as clamp, threads, flanges, tube welding
and non standard tailor made valves !
 PAV 21 PPV 16 PPV 25I
▪ On-off control valves are used whenever one intends to make a remote control of a fluid or in
rough temperature controls, mainly with small flows.
▪ Special attention must be taken with incompressible fluids, if the fluid is in the closing direction,
differential closing pressure is increased, nevertheless serious damages may occur.
 PE 986 PP 981
▪ The pneumatic positioner requires an input signal of 0,2÷1bar
(3÷15psi) for proportional control actuator. The positioner
compares the output signal from a controller with the position
feedback, and varies a pneumatic output signal to the actuator
accordingly. The actuator position is therefore guaranteed for any
controller output signal and the effects of varying differential
pressure.
▪ The electro-pneumatic positioner requires an input signal of 4÷20
mA for proportional control actuator. The positioner compares the
output signal from a controller with the position feedback, and varies
a pneumatic output signal to the actuator accordingly. The actuator
PV 25S
position is therefore guaranteed for any controller output signal and
the effects of varying differential pressure.
Two-way valve arrangement Three – way mixing valve
Fluid : saturated steam arrangement (diverting
regulation) Three – way diverting valve
Fluids: water, diathermic oil, … arrangement
Fluids: water, diathermic oil, …

Three – way mixing valve

Two-way valve arrangement arrangement (mixing regulation)
Fluids: water, diathermic Fluids: water, diathermic oil, …
oil,…
PT – On-off , the flow rate changes from 0 to
100% - fully open or fully closed control.

PL – Linear , the flow capacity or Kv increases

linearly with valve travel . The flow is directely
proportional to the valve travel .Recommended
when there are no relevant variations in
differential pressure or flow rates

EQP – Equal-percentage, for equal increments

of valve plug travel the change in flow rate with
respect to travel may be expressed as a
constant percent of the flow rate at the time of
the change. At constant differential pressure, the
valve travel increase of 10% usually corresponds
to a flow rate increase equal to 50% of the valve
flow preceding the variation. The change in flow
rate observed with respect to travel will be
relatively small when the valve plug is near it’s
seat and relatively high when the valve plug is
nearly wide open.
Recommended when there are wide variations
in flow rate or differential pressure.

▪ The choice of characteristic will depend upon the response required from the control system.
 PARABOLIC PLUG (two-way valve)
PARABOLIC PLUG (two-way valve) Characteristic: linear or equal percentage
Characteristic: linear or equal percentage Flow direction: from below
Flow direction: from below Ratio: 30:1 to 50:1
Ratio: 30:1 to 50:1 Material: stainless steel
Material: stainless steel Sealing: soft sealing-PTFE/Graphite
Sealing: metal to metal Leakage: rate 1, DIN 3230
Leakage: 0,005% of Kvs value Class V acc. DIN60534
Application: steam, water and other fluids Application: steam, water and other fluids and
and gases without cavitation. gases up to 200ºC without
cavitation.

ON/OFF PLUG (two-way valve) ON/OFF PLUG (two-way valve)

Characteristic: none Characteristic: none
Flow direction: from below or above Flow direction: from below or above
Material: stainless steel Material: stainless steel
Sealing: metal to metal Sealing: soft sealing-PTFE/Graphite
Leakage: rate 3 ,DIN3230 Leakage: rate 1 ,DIN3230
Application: shut off of all media Application: shut off of all media up to
200ºC
PERFORATED PLUG (two-way valve) MICROFLOW PLUG (two-way valve)
Characteristic: linear or equal percentage Characteristic: linear or equal percentage
Flow direction: from above Flow direction: from below
Ratio: 30:1 to 40:1 Ratio: 50:1
Material: stainless steel Material: stainless steel
Sealing: metal to metal Sealing: metal to metal
Leakage: 0,005% of Kvs value Leakage: 0,005 of Kvs value
Application: steam, water and other fluids Application: steam, water and other fluids
and gases.Can be use where and gases where extremely low
cavitation flow rates are present.
and flashing is present and if noise
reduction is required.

MIXING PLUG (three-way valve) DIVERTING PLUG (three-way valve)

Characteristic: linear/linear Characteristic: linear /linear
Ratio: 30:1 to 50:1 Ratio: 30:1
Material: stainless steel Material: stainless steel
Sealing: metal to metal Sealing: metal to metal
Leakage: 0,005% of Kvs value Leakage: 0,005 of Kvs value
Application: Water, diathermic oil, … Application: Water, diathermic oil,…
“V” RINGS WITH SPRING GRAPHITE
Type: V1.1 Type G1
Max.pressure : 40bar Max.pressure : 40bar
Max.temperature: 200ºC Max.temperature: 400ºC
Material: PTFE/Graphite Material: Graphite
Application: Steam, water and other fluids Application: Steam, water and other
fluids

“V” RINGS W/SPRING &COOLING FINS

“V” RINGS WITH SPRING
Type: V2.1 Type: V1.1 and VV1.1
Max.pressure : 40bar Max.pressure : 40bar
Max.temperature: 180ºC Max.temperature: 250ºC
Material: PTFE Material: PTFE/Graphite
Application: Steam, water and other fluids Application: Steam, water and other
fluids
 BELLOWS
“V” RINGS WITH SPRINGS
Max.pressure : 25bar
Type: VV1.1
Max.temperature: 400ºC
Max.pressure : 40bar
Material: Stainless steel
Max.temperature: 200ºC
Application: Water,diathermic
Material: PTFE/Graphite
oil,…
Application: Steam, water and other
fluids

Bellow sealed valves are ideal for valves handling dangerous fluids or whenever zero
emissions from valve stem are required.
 POWER SOURCE IMPUT SIGNAL
Low
Pneumatic Electric Hydraulic
Electric Pneumatic Electric
(Or Combination, ie. electro-hydraulic)
Power

FAILURE MODE
Closed Open Fail in Place
 Diaphragm Spring Loaded

Piston Spring Loaded

Reverse Action Direct Action

Air to Open Air to Close

Reverse Action Direct Action

Air to Open Air to Close
 ➢ Questions to ask
▪ What is passing through the valve
▪ Pressure and Temperature
▪ Flow rate
▪ 2 way or 3 way valve
▪ Preferably connections (flanged or threaded)
▪ Pneumatic or Electrically actuated
▪ Pneumatic: spring to open / spring to close
▪ Positioner: I/P 4-20mA or 0-10V
P/P 0,2-1,0 bar (3-15psi)
▪ Body material preference
▪ Application (heat exchanger, jacket vessel , steam cooker, etc)
▪ The valve sizing is based on the calculation of the Kv coefficient.

▪ The formulas, below indicated, allow the Kv calculation in accordance with the type of
fluid and it’s operating condition.

▪ After the Kv calculation, the corresponding Kvs is available from the valve data
sheet. If real operating data have been used for the calculation, as a rule the
calculated Kv should be around 70% to 80% of the selected valve Kvs in order to
guaranty proper regulation of maximum flow rate at the given operating conditions
preventing that sometimes some precautionary additions will result in undesirable
valve over sizing.

▪ At the same time it is necessary to check whether the minimum flow rate can be
even regulated or not considering the chose valve rangeability.

The Kv represents the quantity of water , expressed in cubic meters (m3) at

15ºC, that flows through the valve with a pressure drop of 1 bar , in one hour
period.
 Calculation of Kv value
Medium
Pressure Drop Saturated
Liquids Gases
steam
a)
P1
P2 
2 Kv 
Q2 Q3 d 2  T
Kv 
22,4 Dp  P 2 514 Dp  P 2
P1
Dp 
2 d1
Kv  Q1
b) Dp  1000
P1
P2 
2 Q2 Q3
Kv  Kv  d2T
11,2  P1 257  P1
P1
Dp 
2
Kv Flow coefficient m3/h
P1 Upstream absolute pressure bar
P2 Downstream absolute pressure bar
Dp Pressure drop (P1 – P2) bar
Q1 Flow rate m3/h
Q2 Flow rate Kgs/h
Q3 Flow rate N.m3/h (0ºC – 1013 mbar)
d1 Specific weight of liquid Kg/m3
d2 Specific weight of gas Kg/m3
T Absolute temperature (T=273 + t ºC) ºK
t Fluid temperature ºC
▪ Example 1
Fluid: Saturated steam
Application: temperature control
Control signal: 4÷20mA
Inlet pressure : P1= 6 bar g (7 bar a)
Maximum permissible ΔP : 10%
P2= 5,4bar g (6,4 bar a)
Flow rate: 600Kg/h
P1 Q2 600
Since P 2  , the formula to apply is Kv  then we have: Kv   Kv  13,67m 3 / h
2 22,4 Dp  P 2 22,4 0,6  6,4

To the Kv value calculated from the operating data we add an allowance of at least 10% and thus obtain the
minimum Kvs value which the valve to be selected should have.
Kv  13,67  10%  Kv  15,04m3 / h
We can now select the valve from the datasheet.

Valve selected V25G DN32 PN16.

Now it is necessary to select the actuator : Electric or Pneumatic.
▪ Example 1

Since considered pressure drop

through the valve is negligible we
may consider the maximum
operating pressure (6bar) for the
actuator selection. Thus both the
PA280 with signal 0,4÷1,2bar or
0,4÷2bar can be used.

The valve should be fitted with the

electric-pneumatic positioner PE 986
with an 4÷20mA input signal and
pneumatic output for proportional
actuator control.

NOTE: 0,2÷1bar control signal actuator are recommended for

pneumatic instrumentaion control signal only.
▪ Example 1

In this case the EL12 electric actuator will be enough for the application, also complete with 4÷20mA PEL Positioner.

For a correct request , the desired voltage actuator should be referred.

▪ Example 2

Fluid: Saturated steam

Application: Pressure reducing station
Inlet pressure: P1= 10 bar g (11bar a)
P2=1 bar g (2 bar a)
Flow rate: 13 550Kg/h

P1 Q2
Since P 2  , the formula to apply is Kv  then we have:
2 11,2  P1
13550
Kv   Kv  109,98m 3 / h
11,2  11

To the Kv value calculated from the operating data we add an allowance of at least 10% and thus obtain the
minimum Kvs value which the valve to be selected should have.
Kv  109,98  10%  Kv  120,978m3 / h

Since the pressure drop is too high it is expected some noise on the valve and some vibration on the trim, for
overcame this problems, we should apply a perforated plug.

The perforated plug do not have the nominal seat diameter so we should consult the table for perforated plug and
select the nearest Kvs value.
▪ Example 2

From the table of selection for perforated plugs we can choose a valve DN125 with a 100mm seat diameter and a
Kvs of 121m3/h, that will meet our requirements.

The adequate actuator must now be selected.

➢ Typical Heat Exchanger Temperature Control
 Pressure
transmitter
Pressure
controller

PV25 Control valve

with electro pneumatic
positioner

In liquid service, care must be taken to prevent

cavitation / flashing events.
▪ Whether for industrial efficiency questions or simply for well-being reasons, air’s
humidification is essential in different air conditioning processes, either heating or
cooling.

▪ Humidity quantities added into the air are determined by air’s application, its original
features and by all transformation it will suffer on the treatment systems, such as
temperature changes. That value is usually defined by HVAC designers.

▪ For humidification and when there’s live steam available (hospitals and plants) it’s
common the use of type DSH direct steam humidifiers.
Steam

Adcatrol Steam
Pressure injector
Reducing PV25I
Steam
Valve Air duct
seperator
PRV25
S25

Microflow plug design

Due to little flows sometimes involved, control valves used in these applications are mainly of
reduced bore or even microflow in order to assure a fine control.