CDB 3062

CHEMICAL ENGINEERING LABORATORY III

MAY 2016

EXPERIMENT : CONTROL VALVE CHARACTERISTICS

GROUP : 17

GROUP MEMBERS : ROSLINA AIFAR BINTI ROSLI 19414

MOHD NOOR HADEEF BIN NOOR AZLAN 19431
KOI ZI KANG 18868
MUHAMMAD AMIRUL MUKMIN BIN MARZUKHI 19030
NUR AMALINA BINTI DAWI CAHYONO 19092
LAB INSTRUCTOR : MR. SYED NASIR SYAH

DATE OF EXPERIMENT : 13th JUNE 2016

Table of Contents

1.0 Summary ......................................................................................................................... 1

2.0 Theory ............................................................................................................................. 1

3.0 Objectives ...................................................................................................................... 3

4.0 Procedures ...................................................................................................................... 3

5.0 Results ............................................................................................................................ 4

6.0 Discussions ...................................................................................................................... 9

7.0 Conclusion..................................................................................................................... 11

8.0 References…………………………………………………………………………………………………………………...11

9.0 Appendix……………………………………………………………………………………………………………………...12
1.0 SUMMARY

All control valves have an inherent flow characteristic that defines the relationship
between 'valve opening' and flow rate under constant pressure conditions. Besides, control
valves are very unique in their function in which they can be used to adjust the process
variable such as flow, temperature and pressure. The control valves that we used in this
experiment are linear control valve, quick opening control valves and equal percentage
control valve. In this experiment, we recorded the flow rate and observed the flow
characteristics of these three control valves by adjusting their stroke percentage (0 %, 25%,
50%, 75%, 100%) at two respective constant pressure differences (2.0 psi and 0.5kg/cm2).
From the results obtained, the combined characteristic curves of those three control valves
are almost similar to the theoretical graph for pressure difference of 2.0 psi. However, for
the combined characteristic curves for pressure difference of 0.5kg/cm2, it is slightly
different from the theoretical graph in which the characteristic of linear and equal
percentage control valve were altered. This may be due to systematic error or high pressure
difference. Nevertheless, we may deduce that every type of trim shape for control valve
produces its own unique characteristics which cater for different applications. Selection of
the trim shape for control valve must be done carefully in order to meet the objective of the
related process.

2.0 THEORY

Pneumatic control valves are essential parts of any process control loop to adjust
process variables such as flow, liquid levels, pressure and temperature. Control valves
consist of a valve and an actuator, more valve control elements may also be present in
certain cases.
The relationship between the control valve opening and the flow through valve is
known as the flow characteristic of that valve. An inherent flow characteristic is the relation
between valve opening and flow under constant pressure conditions. The gain of a valve is
defined as the change in flow per unit % change in the valve opening. There are few types of
control valve characteristics as shown below:

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Figure 2.1 Theoretical Characteristic Curves of Quick Opening, Linear, Modified Parabolic and
Equal Percentage Control Valves

 Linear flow characteristic has a constant slope, meaning that valves of this type have
constant gain through complete range of flows. These valves are often used for
liquid level control and certain flow control operations requiring constant gain.
 Equal percentage valves are known by that name because whenever the valve
opening is changed, the percentage change in flow is equal to percentage change in
the valve opening. This means the change in flow proportional to the flow just
before the incremental valve opening is performed. This can also observed in the
following figure. This type of valves is commonly used for pressure control
applications. They can be considered for applications where high variations in
pressure drop are expected.
 Quick opening type of valves does not have a specific mathematical definition. These
valves give a large increment in flow for relatively smaller valve opening, as can be
observed in the following figure. These valves usually find use for on-off service
applications.
 Modified parabolic valves lie somewhere between the linear valves and equal
percentage valves. As can be observed in the following figure, they can be used for
throttling at low flow levels and have almost linear characteristics at higher flows.

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3.0 OBJECTIVES
I. To determine the characteristic curve of a linear control valve.
II. To determine the characteristic curve of an equal percentage control valve.
III. To determine the characteristic curve of a quick opening control valve.

PROBLEM STATEMENT: What kind of characteristic curves will be produced by different types
of trim shapes for control valve (linear, quick opening, equal percentage)?

4.0 PROCEDURES

Linear Control Valve:

1) For linear valve control, all the valves were closed except for valves HV-522, HV-524,
HV-525, HV-530, HV-532 and also HV-533. The power system was switched on and
the pump was switched on accordingly.
2) The stroke percentage was set to 25% while the pressure difference was kept
constant at 2.00 psig accordingly by adjusting one of the valves.
3) The flow rate percentage reading was recorded.
4) The experiment was repeated with stroke percentage being set at 50%, 75% and
100% respectively.
5) Steps 1 to 5 are repeated except that the pressure difference was kept constant at
0.5kg/cm2 by adjusting the same valve but on a different pressure indicator device.

Equal Percentage Control Valve:

1) For linear valve control, all the valves were closed except for valves HV-522, HV-524,
HV-525, HV-530, HV-532 and also HV-533. The power system was switched on and
the pump was switched on accordingly.
2) The stroke percentage was set to 25% while the pressure difference was kept
constant at 2.00 psig accordingly by adjusting one of the valves.
3) The flow rate percentage reading was recorded.
4) The experiment was repeated with stroke percentage being set at 50%, 75% and
100% respectively.

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 5) Steps 1 to 5 are repeated except that the pressure difference was kept constant at
0.5kg/cm2 by adjusting the same valve but on a different pressure indicator device.

Quick Opening Control Valve:

1) For linear valve control, all the valves were closed except for valves HV-522, HV-524,
HV-525, HV-530, HV-532 and also HV-533. The power system was switched on and
the pump was switched on accordingly.
2) The stroke percentage was set to 25% while the pressure difference was kept
constant at 2.00 psig accordingly by adjusting one of the valves.
3) The flow rate percentage reading was recorded.
4) The experiment was repeated with stroke percentage being set at 50%, 75% and
100% respectively.
5) Steps 1 to 5 are repeated except that the pressure difference was kept constant at
0.5kg/cm2 by adjusting the same valve but on a different pressure indicator device.

5.0 RESULTS

i. Pressure Difference = 2.0 psi

Stroke Percentage Flow Rate (%)

(%) 1 Reading 2 Reading 3rd Reading
st nd Average
0 0.00 0.00 0.00 0.00
25 13.63 13.71 13.70 13.68
50 29.36 29.35 29.30 29.34
75 42.76 43.07 43.14 42.99
100 51.74 51.62 51.51 51.62
Table 5.1: Data collected for linear control valve

Stroke Percentage Flow Rate (%)

(%) 1st Reading 2nd Reading 3rd Reading Average
0 0.00 0.00 0.00 0.00
25 35.03 34.96 34.98 34.99
50 49.35 49.40 49.10 49.28
75 51.90 52.06 52.00 51.99
100 50.38 50.20 50.24 50.27
Table 5.2: Data collected for quick opening control valve

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 Stroke Percentage Flow Rate (%)
(%) 1st Reading 2nd Reading 3rd Reading Average
0 0.00 0.00 0.00 0.00
25 2.75 2.78 2.74 2.76
50 8.22 8.28 8.20 8.23
75 28.28 28.19 28.24 28.24
100 50.23 50.15 50.30 50.23
Table 5.3: Data collected for equal percentage control valve

ii. Pressure Difference = 0.5 kg/cm2

Stroke Percentage Flow Rate (%)

(%) 1st Reading 2nd Reading 3rd Reading Average
0 0.00 0.00 0.00 0.00
25 25.13 25.09 25.13 25.12
50 42.43 42.43 42.33 42.40
75 49.65 49.57 49.63 49.62
100 52.48 52.40 52.51 52.46
Table 5.4: Data collected for linear control valve

Stroke Percentage Flow Rate (%)

(%) 1st Reading 2nd Reading 3rd Reading Average
0 0.00 0.00 0.00 0.00
25 51.38 51.62 51.45 51.48
50 56.55 56.71 56.54 56.60
75 56.85 56.63 56.60 56.69
100 56.42 56.36 56.27 56.35
Table 5.5: Data collected for quick opening control valve

Stroke Percentage Flow Rate (%)

(%) 1st Reading 2nd Reading 3rd Reading Average
0 0.00 0.00 0.00 0.00
25 5.67 5.66 5.69 5.67
50 15.37 15.40 15.39 15.39
75 39.85 39.87 39.90 39.87
100 49.67 49.80 49.74 49.74
Table 5.6: Data collected for equal percentage control valve

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 Flow Rate Percentage vs Stroke Percentage
60.00

Flow Rate Percentage (%)

50.00

40.00

30.00

20.00

10.00

0.00
0 20 40 60 80 100 120
Stroke Percentage (%)

Graph 5.1: Characteristic curve for linear control valve (Pressure difference = 2.0 psi)

Flow Rate Percentage vs Stroke Percentage

60.00
Flow Rate Percentage (%)

50.00

40.00

30.00

20.00

10.00

0.00
0 20 40 60 80 100 120
Stroke Percentage (%)

Graph 5.2: Characteristic curve for quick opening control valve (Pressure difference = 2.0 psi)

Flow Rate Percentage vs Stroke Percentage

60.00
Flow Rate Percentage (%)

50.00

40.00

30.00

20.00

10.00

0.00
0 20 40 60 80 100 120
Stroke Percentage (%)

Graph 5.3: Characteristic curve for equal percentage control valve (Pressure difference = 2.0
psi)

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 Flow Rate Percentage vs Stroke Percentage
60.00

Flow Rate Percentage (%)

50.00

40.00

30.00 Linear

20.00 Quick
Equal
10.00

0.00
0 20 40 60 80 100 120
Stroke Percentage (%)

Graph 5.4: Combined characteristic curves for all control valves (Pressure difference = 2.0psi)

Flow Rate Percentage vs Stroke Percentage

60.00
Flow Rate Percentage (%)

50.00

40.00

30.00

20.00

10.00

0.00
0 20 40 60 80 100 120
Stroke Percentage (%)

Graph 5.5: Characteristic curve for linear control valve (Pressure difference = 0.5kg/cm2)

Flow Rate Percentage vs Stroke Percentage

60.00
Flow Rate Percentage (%)

50.00

40.00

30.00

20.00

10.00

0.00
0 20 40 60 80 100 120
Stroke Percentage (%)

Graph 5.6: Characteristic curve for quick opening control valve (Pressure difference =
0.5kg/cm2)

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 Flow Rate Percentage vs Stroke Percentage
60.00

Flow Rate Percentage (%)

50.00

40.00

30.00

20.00

10.00

0.00
0 20 40 60 80 100 120
Stroke Percentage (%)

Graph 5.7: Characteristic curve for equal percentage control valve (Pressure difference =
0.5kg/cm2)

Flow Rate Percentage vs Stroke Percentage

60.00
Flow Rate Percentage (%)

50.00

40.00

30.00 Linear
Quick
20.00
Equal
10.00

0.00
0 20 40 60 80 100 120
Stroke Percentage (%)

Graph 5.8: Combined characteristic curves for all control valves (Pressure difference
0.5kg/cm2)

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6.0 DISCUSSIONS

The purpose of this experiment is to determine the characteristic curve of a linear

control valve, an equal percentage control valve and a quick opening control valve
respectively. The relationship between the control valve opening which is also known as
valve travel, and the flow through valve is known as the flow characteristic of that valve.

For the first part of experiment, we adjusted one of the valves to keep the
differential pressure at 2 psig constantly. From graph 5.1 (linear), we can identify a nearly
constant slope in which the flow rate percentage increases linearly proportional to the
stroke percentage. This means that the linear control valve has constant gain through
complete range of flows. From graph 5.2 (quick opening), the flow rate percentage increases
largely when there is a small change of stroke percentage. From graph 5.3 (equal
percentage), the flow rate percentage increases exponentially with the stroke percentage.
This means that when the valve opening is changed, the percentage change in flow is equal
to percentage change in the valve opening. From graph 5.4, we can see a clear and distinct
similar characteristics shown by each respective characteristic curve of linear, equal
percentage and quick opening control valve as compared with its theoretical graph as
shown in figure 2.1.

For the second part of experiment, we adjusted the same valve but different
pressure indicator device to keep the differential pressure constant at 0.5 kg/cm 2. From
graph 5.5 (linear), we can see that the linear control valve produces a near square root
characteristic but it can be considered as a linear curve in system. From graph 5.6 (quick
opening), the flow rate percentage increases largely when there is a small change of stroke
percentage From graph 5.7 (equal percentage), we can see that the equal percentage
characteristic gets close to linear flow. From graph 5.8, we can see a slight different
characteristic of each characteristic curve of control valve installed in system as compared
to the inherent characteristic shown in theoretical graph. This difference might be caused by
the high pressure drop which alter the characteristic. The other possible reason is that the
pressure indicator device controlled in this part of experiment is not accurate and not well
calibrated in producing the characteristic curve that is similar to the theoretical graph.

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 For liquid level control and certain flow control operations that require constant
gain, linear control valves are often used as the pressure drop across the system is low at
the required flow rate and the pressure drop across the linear control valve will not
significantly alter. Quick opening control valves are usually used for on-off service
applications as those applications need a rapid response to achieve its on-off function. Equal
percentage valves are commonly used for pressure control applications. They can be
considered for applications where high variations in pressure drop are expected.

ERRORS & RECOMMENDATIONS

i. Error: The pressure and flow rate readings fluctuates very frequently.
Recommendation: Take at least three readings and calculate the average to get a
more accurate result.

ii. Error: The percentage opening control knob is too sensitive which makes it difficult
to control the value.
Recommendation: Change the percentage opening control knob to the less sensitive
control knob so it is easy to control as well as keeping a steady hand when turning
the knob.

iii. Error: The readings on the pressure difference might be incorrect due to parallax
error.
Recommendation: Make sure eye as on the same level as the pressure meter when
taking the reading.

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7.0 CONCLUSION

In summary, there are three types of trim shapes for control valve that are used in this
experiment which are linear, quick opening, and equal percentage. In the first part of
experiment, when the pressure difference is at 2 psig, the linear control valve produces a
constant slope line in the graph of flow rate percentage versus stroke percentage which is
proven by the theory. Secondly, the graph of flow rate percentage versus stroke percentage
is also corresponded with the theory as it increases largely when there is a small change of
stroke percentage. Lastly, the equal percentage control valve is also tallied with the theory as
the graph of flow rate percentage versus stroke percentage produced increases
exponentially. However, when the pressure is kept constant at a higher pressure which is 0.5
kg/cm2, the characteristics of linear and equal percentage are altered. In this context, the
linear control valve produces a near square root trend whereas equal percentage control
valve produces a near linear graph. This might be due to high pressure difference or
systematic error. Linear control valve is suitable for liquid level control while equal percentage
control valve is suitable for pressure control applications whereas quick opening control valve
is suitable for on-off applications. In conclusion, the characteristic curves of all three types of
trim shapes of control valve are determined and selection of the type depends on its
suitability onto the needed application.

8.0 REFERENCES

Control Valves, n.d., 18 June 2016, from http://www.enggcyclopedia.com/2011/05/control-

valves/

Controller Theory, n.d., 18 June 2016, from

http://www.marineengineering.org.uk/page96.html

Controlling Flow With Ball Valves, n.d., 17 June 2016, from

http://www.industrialcontrolsonline.com/training/online/controlling-flow-ball-
valves

Seborg, D. E., Edgar, T. F., Mellichamp, D. A. & Doyle, F. J. (2004). Process Dynamics and
Control (3rd ed.). United States of America: John Wiley & Sons, Inc.

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9.0 APPENDIX

Figure 1: The overall equipment used in this experiment

Figure 2: Control panel of the equipment

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Figure 3: Mechanical pressure gauge used to keep the pressure at 0.5 kg/cm2

Figure 4: Digital pressure gauge used to keep the pressure at 2 psig

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