ERT 422/4

Piping and instrumentation diagram

(P&id)
1.What valve 2. How it’s
VALVES
means? work?

IN
INDUSTR
Y

3. Classification of
valves?
 INTRODUCTION TO
VALVES
 Mechanical devices specifically designed to
direct, start, stop, mix or regulate the flow,
pressure or temperature of a process fluid.
 Manufactured from various materials, mostly
made from steel, iron, plastic, brass, bronze
and special alloys.
 1. Function

VALVES 2. Application
CLASSIFICATION

3. Motion
 1. Function

VALVES 2. Application
CLASSIFICATION

3. Motion
VALVES CLASSIFICATION
ACCORDING TO FUNCTION

Categorized into three areas:

1) On-Off Valves
2) Non return Valves
3) Throttling Valves

Specific valve-body designs may fit into one, two, or

all three category.
 VALVES VALVES
CLASSIFICATION
CLASSIFICATION
ACCORDING TO FUNCTION
ACCORDING TO FUNCTION
1) On-Off Valves
 Start or stop the flow of the medium through the process.
 Example: gate, plug, ball and pressure-relief valves.
 Can be hand-operated or automated with the addition of an actuator.
 Used in mixing applications where a number of fluids are combined for a
predetermined amount of time (exact measurements are not required).
 Used for immediate shut down of a system when an emergency situation
occurs.
 Pressure-relief valves are self-actuated on-off valves that open only
when a preset pressure is surpassed.
 Used for guarding against over pressurization of a liquid service.
 Applied in gas applications where over pressurization of the system
shows a safety or process hazard and must be vented.
On-Off Valves
 VALVES VALVES
CLASSIFICATION
CLASSIFICATION
ACCORDING TO FUNCTION
ACCORDING TO FUNCTION
2) Non return Valves
 Allow the fluid to flow only in the desired direction.
 Any flow or pressure in the opposite direction is mechanically restricted
from occurring.
 All check valves are non return valves.
 Backflow of fluid is prevented to ensure the safety of equipment and
the desired dynamic of the process.
 Applied in process systems that have varying pressures, which must be
kept separated.
 VALVES VALVES
CLASSIFICATION
CLASSIFICATION
ACCORDING TO FUNCTION
ACCORDING TO FUNCTION
3) Throttling Valves

 Used for regulating the flow, temperature or pressure of the

service.
 Can be moved to any position within the stroke of the valve and
hold that position, including the fully-open or fully-closed
positions.
 Also provided with actuation system for greater thrust and
positioning capability (automatic control).
 Example: pressure regulator varies the valve’s position to maintain
constant pressure downstream (close to decrease and open to
increase the pressure).
 Control valves are valves that are capable of varying flow
conditions to match the process requirements (always equipped
with actuators).
Throttling Valves
 1. Function

VALVES 2. Application
CLASSIFICATION

3. Motion
 Valves Classification
According To Application

Categorized into three:

1) General Service Valves
2) Special Service Valves
3) Severe Service Valves
 Valves Classification
According To Application
1) General Service Valves
 Designed for the majority of the commonplace
applications that have lower-pressure ratings,
moderate-temperature ratings, noncorrosive fluids
and common pressure drops that do not result in
cavitation or flashing.
 Had some degree of interchangeability and
flexibility for wider range of applications.
 Valves Classification
According To Application
2) Special Service Valves
 Designed for a single application that is outside
normal process applications (custom-engineered
valves).
 Handled a demanding temperature, high pressure or a
corrosive medium.
 Valves Classification
According To Application
3) Severe Service Valves
 Equipped with special features to handle volatile
applications and high pressure drops (highly engineered
trims).
 Special actuation may be required to overcome the
forces of the process.
 1. Function

VALVES 2. Application
CLASSIFICATION

3. Motion
 Valves Classification
According To Motion

Categorized into two:

1) Linear-motion Valves

2) Rotary-motion Valves
 Valves Classification
According To Motion
1) Linear-motion Valves
 Had a sliding-stem design that pushes a closure
element into an open or closed position.
 Simple design, easy maintenance, and versatile
with various sizes, pressure class and design
options.
 Example: gate, globe, diaphragm, three-way.
Linear-motion Valves
 Valves Classification
According To Motion

2) Rotary-motion Valves
 Used a closure element that rotates through a
quarter-turn range to open and block the flow.
 Limited to certain pressure drops.
 Prone to cavitations and flashing problems.
Rotary-motion Valves
COMMON PIPING NOMENCLATURE

 Heavily influenced by imperial system, ANSI,

e.g. psi for pressure, nominal pipe size (NPS)
for valve, inches for pipes.
 Metric system widely used in Asia, e.g. kpa or
bar for nominal pressure (PN), nominal
diameter (DN), mm for pipes.
COMMON PIPING NOMENCLATURE

NPS versus DN ANSI Pressure versus PN

inches millimeters psi bar
0.25 6 150 16
0.5 15 300 40
1.0 25 600 100
2.0 50 900 160
4.0 100 1500 250
8.0 200 2500 400
16.0 400 4500 700

Note:
Note: PN
PN correlates
correlates to
to DIN
DIN (Deustche
(Deustche Industrie
Industrie Norme)
Norme) pressure-temperature
pressure-temperature
rating
rating standards,
standards, which
which may
may vary
vary significantly
significantly from
from ANSI
ANSI pres.-temp.
pres.-temp. ratings.
ratings.
TYPES OF VALVES
IN INDUSTRY
TYPES OF
VALVES IN
INDUSTRY
TYPES OF
VALVES IN
INDUSTRY
 The most common final control elements.
Function- control system by adjusting the flows that affect the
globe valves,
controlled variable.
butterfly valves,
Final
ball valves,control elements include control valves, metering pumps,
eccentric
dampers and louvers,
disc valves and variable pitch fan blades, and electrically driven
diaphragm valves
control devices.
Can operated
The control valve is the most widely used type of final control element
1)Manual (Human)
and it (Actuators)
2)Automatic must perform satisfactorily with a minimum amount of
Hydraulics
maintenance attention, even in severe conditions of temperature,
Air (pneumatic)
pressure, corrosion and contamination .
Electrical/ Magnetic
A control valve functions as variable resistance in a pipeline. It
provides pressure drop, called throttling, which limits the flow through
a pipeline.
 There are many different kinds of control valves in
common use:
globe valves,
globe
butterfly valves, valves,
butterfly valves,
ball valves,
eccentric
ball
disc valves,
valves and
diaphragm valves
eccentric disc valves and
Can operated
diaphragm valves
1)Manual (Human)
Can operated;
2)Automatic (Actuators)
Hydraulics
Manual (Human)
Air (pneumatic)
Electrical/
Automatic
Magnetic (Actuators)
Hydraulics
Air (pneumatic)
Electrical/ Magnetic
TYPES OF
VALVES IN
INDUSTRY
 The valve is devided into 2 general areas;
i) Actuators- is the part of the valve that converts the electrical/ pressure energy
input to the valve into mechanical motion (stem) to increase or decrease the
globe valves,
flow restriction
butterfly valves,

ii) Body- contains and regulates the fluid flow
ball valves,
eccentric disc valves and
A type of valve for regulating flow in a pipeline, consisting of a movable disk-
diaphragm valves
type element and a stationary ring seat in a generally spherical body.
Can operated
Named for their spherical body shape with the two halves of the body being
1)Manual (Human)
separated
2)Automatic by an internal baffle. This has an opening that forms a seat onto
(Actuators)
Hydraulics
which a movable plug (also called a disc) can be screwed in to close the valve.
AirThe
(pneumatic)
disc is connected to a stem which is operated by screw action in manual
Electrical/ Magnetic
valves. Typically, automated valves use sliding stems.
Automated globe valves have a smooth stem rather than threaded and are
opened and closed by an actuator assembly.
 The bonnet assembly is
the part of the valve
body through which the
valve plug stem moves.
  Globe valve bodies can be classified as :
globe valves,
 direct
butterfly valves, acting valve body - a downward movement of the
valve plug stem results in the valve closing.
ball valves,
eccentric disc valves
 reverse and valve body - a downward movement of the
acting
diaphragm valves
valve plug stem results in the valve opening.
Can operated
1)Manual (Human)
2)Automatic (Actuators)
Hydraulics
Air (pneumatic)
Electrical/ Magnetic
  A globe valve can
globe valves,
contain
butterfly valves, either one or
two plugs. When there
ball valves,
eccentric
is only one
disc valves andplug/disc,
diaphragm valves
the valve is called
Can operated
single ported globe
1)Manual (Human)
valve.
2)Automatic (Actuators)
Hydraulics
 When there are two
Air (pneumatic)
plugs,
Electrical/ it is called a
Magnetic
double-ported globe
valve.
  The double-ported valve arrangement produces almost no
unbalanced force on the valve stem.
globe valves,
 The fluid flows through the valve ports in opposite directions
butterfly valves,
and therefore generates forces that offset each other.
ball valves,
 As disc
eccentric a result, only a relatively small actuator force is needed
valves and
diaphragm
for positioning
valves the valve plugs.
Can operated
 This
1)Manual makes the double-ported globe valve suitable for high
(Human)
pressure
2)Automatic applications.
(Actuators)
Hydraulics
 Globe valves are used for applications requiring throttling
Air (pneumatic)
and frequent operation.
Electrical/ Magnetic
 Globe valves are the most frequently encountered control
valves in process plants.
globe valves,
butterfly valves,
ball valves,
eccentric disc valves and
diaphragm valves
Can operated
1)Manual (Human)
2)Automatic (Actuators)
Hydraulics
Air (pneumatic)
Electrical/ Magnetic
TYPES OF
VALVES IN
INDUSTRY
  Used when a straight-line flow of fluid and minimum
globe valves,
restriction is desired.
butterfly valves,
ball The gate is usually wedge shaped. When the valve is
valves,
eccentricwide open,
disc valves and the gate is fully drawn up into the valve,
diaphragmleaving
valves an opening for flow through the valve the same
size as the pipe in which the valve is installed.
Can operated
 Therefore,
1)Manual (Human) there is little pressure drop or flow
restriction
2)Automatic (Actuators) through the valve.
Hydraulics
 Gate valves are not suitable for throttling purposes
Air (pneumatic)
since the control of flow would be difficult due to valve
Electrical/
design
Magneticand since the flow of fluid slapping against a
partially open gate can cause extensive damage to the
valve.
globe valves,
butterfly
 Can valves,be classified as:
ball valves,
eccentric
1) rising stem
disc valves and valves - the stem
diaphragm valves
attached to the gate; the gate
Can operated
and stem rise and lower
1)Manual (Human)
together
2)Automatic (Actuators) as the valve is
operated.
Hydraulics
Air (pneumatic)
Electrical/ Magnetic
globe valves,
butterfly valves,
2) non-rising stem valves - the stem is
ball valves,
threaded on the lower end into
eccentric disc valves and
diaphragmthevalves
gate. As the hand wheel on the
stem is rotated, the gate travels up
Can operated
1)Manual or down the stem on the threads,
(Human)
while
2)Automatic the stem remains vertically
(Actuators)
Hydraulics
stationary.
Air (pneumatic)
Electrical/ Magnetic
TYPES OF
VALVES IN
INDUSTRY
 Stop valves that use a ball to stop or start the flow of
fluid.
 The ball rotates to a point where the hole through the
ball is in line with the valve body inlet and outlet.
 When the valve is shut, which requires only a 90-
degree rotation of the hand wheel for most valves, the
ball is rotated so the hole is perpendicular to the flow
openings of the valve body, and flow is stopped.
 Most ball valves are of the quick-acting type (requiring
only a 90-degree turn to operate the valve either
completely open or closed), but many are planetary
gear operated.
 This type of gearing allows the use of a relatively small
hand wheel and operating force to operate a fairly large
valve. The gearing does, however, increase the
operating time for the valve.
 Some ball valves contain a swing check located within
the ball to give the valve a check valve feature.
 Ball valves are normally found in the following systems
aboard ship: seawater, sanitary, trim and drain, air,
hydraulic, and oil transfer.
TYPES OF
VALVES IN
INDUSTRY
 Has a relatively small orifice with a long, tapered,
conical seat. A needle-shaped plunger, on the end of
a screw, exactly fits this seat.
 As the screw is turned and the plunger retracted,
flow between the seat and the plunger is possible;
however, until the plunger is completely retracted
the fluid flow is significantly impeded.
 Precise regulation of the flow rate is possible.
 Used in flow metering applications, especially when a
constant, calibrated, low flow rate must be maintained for
some time, such as the idle fuel flow in a carburetor.
 Since flow rates are low and many turns of the valve stem
are required to completely open or close, needle valves
are not used for simple shutoff applications.
 Since the orifice is small and the force advantage of the
fine-threaded stem is high, needle valves are usually easy
to shut off completely, with merely "finger tight" pressure.
 Small, simple needle valves are often used as bleed valves
in hot water heating applications.
TYPES OF
VALVES IN
INDUSTRY
 Nearly all hand-operated valves in large
refrigeration systems are diaphragm valves.
 The fluid has to rise up and over a seat. There is a
pressure drop through this type of valve.
 The upper part is sealed off from the lower part by a
diaphragm.
 An upward-seating ball check in the lower valve
stem makes it possible for the spring to lift the
lower stem regardless of pressure differences
developed while the valve was closed. Thus, the
valve will operate properly regardless of direction
of flow.
 Can be tightened by hand enough to hold back high
pressures.
 Can be installed into the system with either a flare
or soldered connection.
 When it is soldered, care should be taken that it is
not overheated.
 Most of these valves have seats made of materials
that would not melt when the valves was being
soldered into a line.
TYPES OF
VALVES IN
INDUSTRY
 An electrically operated valve where an electromagnet
is used as an actuator to change the valve state.
 Used only in an ON/OFF manner. In a two-way solenoid
valve, the valve is open when the solenoid coil is
energized.
 The energized solenoid
coil acts as an
electromagnet which
pulls the plunger and
the valve disc upwards.
 The valve is closed
when the coil is de-
energized.
 The closing action of the
valve is achieved by the
weight of the plunger,
valve stem and disc.
 Once the disc comes
close to its seat, flow
(from left hand side) will
snap the valve tightly
shut
 In a three-way solenoid valve, energizing the
solenoid coil causes the valve to open from Port 1 to
Port 2 while deenergizing the coil causes the valve
to open from Port 2 to 3.
 A solenoid valve is often used in conjunction with a
pneumatically actuated diaphragm control valve to
obtain ON/OFF valve operation by an electrically
applied signal.
 This arrangement,
depending on the valve
size, may be much more
reliable, more powerful,
less expensive and
faster responding than
using an all electric
control valve.
TYPES OF
VALVES IN
INDUSTRY
 A control valve actuator is a device which is used to
drive the valve plug stem and therefore sets the
position of the plug with respect to the valve seat.
 The most common valve actuator is the pneumatic
diaphragm actuator. It is simple in construction and
very reliable. It operates by the injection of a single,
low pressure air signal into the diaphragm housing.
 The diaphragm housing is
made up of two sections
separated by a flexible
diaphragm.
 The air pressure applied on
the diaphragm develops a
working force. This force is
transmitted to the actuator
stem via the diaphragm plate,
which is a supportive metal
disk attached to the
diaphragm.
 The actuator spring provides a
restoring force which
positions and returns the
actuator stem.
 The choice between direct acting and reverse acting
pneumatic controls depends on what position the
valve should revert to in the event of failure of the
compressed air supply.
i.e. it depends upon the nature of the application and
safety requirements.
 It makes sense for steam valves to close on air failure,
and cooling valves to open on air failure.
 Piston actuators are generally used where the stroke of
a diaphragm actuator would be too short or the thrust is
too small.
 The compressed air is applied to a solid piston
contained within a solid cylinder.
 Piston actuators can be single acting or double acting,
can withstand higher input pressures and can offer
smaller cylinder volumes, which can act at high speed.
TYPES OF
VALVES IN
INDUSTRY
 Pneumatic valve positioners are the most
commonly used valve accessories.
 A valve positioner is a device which will accurately
position a control valve in accordance with the
pneumatic control signal.
 The control signal is routed to the positioner where
comparison of the valve position (actual) to the
control signal (desired) is used to develop an output
pneumatic signal which operates the valve actuator.
 The positioner compares the control signal (the requested
valve position) with the actual valve position through the
mechanical feedback linkage.
 If the valve position is incorrect, the positioner will either
load or exhaust air from the valve actuator until the
correct valve position is obtained.
 A positioner requires both a control signal and an
instrument supply air for normal operation.
 Most positioners come equipped with three gauges to
indicate supply air pressure, control signal pressure and
actuator diaphragm signal (output) air pressure.
 Advantages of the valve positioner include:
1) Minimizing the effect of friction, hysteresis and
deadband on the valve stem. With a high pressure
system, tighter valve stem packing is needed to
prevent leakage and a high frictional force is
generated. With a positioner valve stem
movements of as little as 25 µm are possible.
2) Enables signal range change. A positioner can
amplify the incoming control signal when a greater
actuating force is needed. A 20-100 kPa control
signal can be amplified to 40-200 kPa before being
applied to the actuator.
 PIPING AND INSTRUMENTATION DIAGRAM (P&ID)

Question 1
 Figure below shows the liquid vessel for boiler system. This system has to maximum
desired temperature of 120 oC (L2) where the heater will be cut off when the temperature
reached desired temperature. Draw feedback control loop for the system.

Fluid in

V-100

Fluid out
V 100
 PIPING AND INSTRUMENTATION DIAGRAM (P&ID)

Answer 1
 Figure below shows the liquid vessel for boiler system. This system has to maximum
desired temperature of 120 oC (L2) where the heater will be cut off when the temperature
reached desired temperature. Draw feedback control loop for the system.

TC

Fluid in

V-100 TT

Fluid out
V 100
 PIPING AND INSTRUMENTATION DIAGRAM (P&ID)

Feedforward-plus-Feedback Control
 Because of the difficulty of accounting for every possible load disturbance in a
feedforward system, this system are often combined with feedback systems.
 Controller with summing functions are used in these combined systems to total the
input from both the feedforward loop and the feedback loop, and send a unified
signal to the final control element.

FC TC

FT Process variable need to

Fluid in be controlled =
TT
Temperature
Y

Steam Fluid out

LCV-100
 PIPING AND INSTRUMENTATION DIAGRAM (P&ID)

Exercise 1
 Figure below shows the boiler system that used to supply hot steam to a turbine.
This system need to supply 100 psi hot steam to the turbine where the PCV-100 will
be opened when the pressure reached that desired pressure. With using pressure
control through temperature and pressure measurement in the boiler, draw a
feedforward-plus-feedback control loop system.

Water Hot steam

Process variable need to

be controlled = Pressure
BOILER
 PIPING AND INSTRUMENTATION DIAGRAM (P&ID)
Answer 2
 Figure below shows the boiler system that used to supply hot steam to a turbine. This
system need to supply 100 psi hot steam to the turbine where the PCV-100 will be opened
when the pressure reached that desired pressure. With using pressure control through
temperature and pressure measurement in the boiler, draw a feedforward-plus-feedback control
loop system.


TIC PIC
Y

TT PT

Water Hot steam

Process variable need to

be controlled = Pressure
BOILER
THANK YOU