Control Valves &safety Valves
Control Valves &safety Valves
Control Valves &safety Valves
Control valves
• Any Hazard that finally goes to disastrous event it should cross all the above
independent protection layers . Control valves comes under basic process
control systems and safety valves comes under physical protection(relief
devices).
What is control valve?
control valve Performs a special task ,controlling the flow of fluids so a process
variable such as fluid Pressure, fluid level and fluid temperature.
In addition to these control valve may be used to shut off flow.
It is a valve with powered actuator that responds to an external signal, that signal
usually comes from controller.
Control valve
Control valve working
Basic Terminology
:The flow Coefficient
:liquid pressure recovery coefficient
Choked flow
Cavitation
Flashing
Flow coefficient (:
Dimensionless quantity related to valves flow Capacity. It technically defined as
volume of water at 60F that flow through the valve per minute with a pressure
drop of 1Psi across the valve.
=
Value increases if the flow rate increases or if the pressure drop decreases.
liquid pressure recovery coefficient
When a fluid passes though the vena contracta(point at which cross sectional area is
minimum),velocity is at maximum.
By conservation energy since the kinetic energy reaches to maximum, potential energy
in the form of static Pressure, must decrease to minimum.
Down stream of vena contracta fluid starts decelerates consequently pressure
increases or recovers.
=
If is 1,the vena contracta pressure would be same as the valves outlet pressure and
there would be no recovery.
As the valve smaller the vena contracta pressure decreases to a lower value and the
valve is more likely to cavitate.
Choked flow :
The linear relationship between flow rate and pressure drop does not always true as
the pressure drop increased by lowering the downstream pressure, flow rate at one
point will increase and it will be constant.
when the pressure at the vena contracta is slightly below the vapor pressure of
liquid, it starts vaporizing.
When the additional decrease in down stream pressure cause more bubbles are
formed.
These vapour bubbles restrict the flow of liquid until the liquid is filly choked
with vapour.
This condition is “choked flow” or “critical flow”
Cavitation:
As the bubbles move down the stream, area of cross section increases, velocity starts
decreasing and pressure increases.
Now we have the bubbles with internal pressure equal to vapor pressure and surrounded by
higher Pressure due to this bubbles will collapse making a popping sound.
As the bubbles collapse they create shock waves that can cause severe damage to the
valve.
Cavitation will have four negative effects in control valves
Advantages Disadvantages
Advantages Disadvantages
Low pressure drop, low leakage, small, Seat can wear if used for throttling,
rapid opening. quick open may cause hammer.
Low cost and weight relative to globes as Over sizing
size increases High cost in large sizes compared to
High flow capacities (2 to 3 times that of butterfly valves.
globe valves)
Tight shutoff
Low stem leakage
Easily fitted with quarter turn actuators
Butterfly valves
The “butterfly” element is a disk that rotates perpendicular to the path of fluid
flow. When parallel to the axis of flow, the disk presents minimal obstruction;
when perpendicular to the axis, the disk completely blocks any flow.
Butterfly valves are simple and take up little space. This makes them especially
good for use in large pipelines or where there is not much space.
Operating a butterfly valve can take a lot of force as you have to push it against
the fluid pressure. Larger valves usually have geared actuators to make operation
easier.
Butterfly valves
Applications:
Low pressure, large diameter lines where leakage is unimportant.
Advantages Disadvantages
Gate valve:
Best suited control : Quick opening
Globe valve:
Best suited control : linear and equal percentage
Ball valve:
Best suited control : Quick Opening , linear
Butterfly valve:
Best suited control : linear and equal percentage
Valve failure modes
Control valve failure means the loss of the source of the actuating power
supplied to the valve body .
Valve failure modes
Safety valves
What is safety valve?
Safety Valve is a type of valve that
automatically actuates when the pressure of
inlet side of the valve increases to a
predetermined pressure, to open the valve
disc and discharge the fluid.
Safety valve is an automatic mechanical
device which can work in abnormalities like
power, air, utility failure.
Basic Terminology
Safety valve :A pressure relief valve actuated by inlet static pressure and
characterized by rapid opening or pop action .
Safety valves are primarily used with compressible gases and in particular for
steam and air services.
Relief valves :A pressure relief device actuated by inlet static pressure having
a gradual lift generally proportional to the increase in pressure over opening
pressure.
Relief valves are commonly used in liquid systems, especially for lower
capacities and thermal expansion duty. They can also be used on pumped
systems as pressure overspill devices.
Safety relief valve (SRV): An automatic system that relieves by static
pressure on both gas and liquid.
Basic Terminology
Back Pressure : Static pressure existing at the outlet of a pressure relief device
due to pressure in the discharge system.
Super imposed back pressure: Static pressure that exists on the outlet side of
closed valve.
Built-up back pressure: Additional pressure generated on the outlet side
when the valve is discharging. This is because there Head/friction loss
(Pressure drop) in the pressure relief system
Pressure Terminology
Codes and standards
API RP 510. Pressure Vessel Inspection Code.
Part 1 : Sizing selection and installation of
API 520 Part 1. pressure relieving .
API 520 Part 2. Part 2 Installation.
Guide for pressure relieving and de-
API 521.
pressurising systems.
API 526 Flanged steel pressure relief valves.
API 527. Seat tightness of pressure relief valves.
Advantages:
Most reliable type if properly sized and operated
Versatile- can be used in many services.
Disadvantages:
Relieving pressure affected by back pressure
Susceptible to chatter if built up back up pressure is too high
Safety relief valve design
Balanced bellow safety relief valve:A
balanced valve incorporates a means of
minimizing the effect of backpressure on
the operational characteristics of the valve.
Safety relief valve design
Balanced bellow safety relief valve
Advantages:
Relieving pressure not affected by back pressure
Can handle higher built back up pressure
Protects spring from corrosion
Disadvantages:
Bellows susceptible to fatigue/rupture
May release flammable/toxics to atmosphere
Requires separate venting system
Safety relief valve design
Pilot operated safety relief valve:The major relieving device is combined
with, and is controlled by, a self-actuated auxiliary pressure relief device.
Advantages
Relieving pressure not affected by backpressure.
Can operate at up to 98% of set pressure
Less susceptible to chatter (some models)
Disadvantages
Pilot is susceptible to plugging.
Limited chemical and high temperature use by “O-ring” seals
Vapor condensation and liquid accumulation above the piston may cause
problems
Potential for back flow
Chatter
Chattering is rapid ,alternating opening and closing of PR valve.
Resulting vibration may cause misalignment, valve seat damage and if
prolonged ,can cause mechanical failure of valve internals and associated
piping
Chatter may occur in either liquid or vapour services.
Principal causes
Excessive inlet pressure drop
Excessive built up back up pressure
Oversized valve
Valve handling widely differing rates
Inlet line considerations:
Inlet line size must be at least equal to PRV inlet flange size
Advantages:
Reduced fugitive emissions - no simmering or leakage prior to bursting.
Protect against rapid pressure rise cased by heat exchanger tube ruptures or
internal deflagrations.
Less expensive to provide corrosion resistance.
Less tendency to foul or plug.
Provide both over pressure protection and depressurizing.
Provide secondary protective device for lower probability contingencies
requiring large relief areas
Disadvantages
Don’t reclose after relief.
Burst pressure cannot be tested.