CH4030: Process Control Lab

Experiment 1: Valve Characteristic

Date of Experiment: 21/08/2023

Group: P7

CH20B031 Dagani Susheel Gowtham

CH20B032 Deva Pradha Abinidhi R

CH20B033 Devang Tiwari

CH20B034 Devi Minnu V A
CH20B035 Devulapally Ujwala
OBJECTIVE
The objective is to analyze the valve traits across various types and examine the
correlation between the degree of valve aperture and the corresponding flow rate.

APPARATUS USED
Control Valve trainer with ON/OFF valve, Equal Valve and Linear Valve.

PROBLEM AND METHODOLOGY

Our focus revolves around investigating the distinctive traits exhibited by various valves,
including ON/OFF Control Valves, Equal Control Valves, and Linear Control Valves.
Our aim involves plotting the relationship between stem aperture and flow rates. The
traits being explored pertain to Inherent Flow characteristics, typically represented
graphically. These attributes are established through laboratory-based assessments,
involving the measurement of valve flow against valve lift while applying a differential
pressure drop across the valve.

THEORY
Final control elements or actuators are devices that enable the process variable to be
manipulated. For most chemical and petroleum processes, the final control elements (usually
control valves) adjust the flow rates of materials-solid, liquid, and gas feeds and products-and,
indirectly, the rates of energy transfer to and from the process. There are many different ways
to manipulate the flows of material and energy into or out of a process; for example, the speed
of a pump drive, screw conveyor, or blower can be varied. However, a simple and widely
used method of accomplishing this result with fluids is to use a control valve.
The valves can be differentiated based on flow characteristics and how they vary with
stem opening and other parameters. The three most common types of flow characteristics
are ON/OFF, Equal Percentage, and Linear.

ON/OFF Control Valve:

An ON/OFF Valve functions as the hydraulic equivalent of an electrical switch, serving
as a mechanism that either allows fluid to flow unhindered or completely blocks its
passage. These valves find extensive application in directing process fluids to various
destinations, initiating and halting batch processes, and enacting automated safety
measures for shutdown scenarios. The operation of an On-Off valve is binary, operating
solely in either a fully open or fully closed state. This inherent characteristic excludes the
possibility of regulating flow at intermediary levels, rendering them unsuitable for
throttling purposes. An apt analogy can be drawn with a tap utilized to fill an overhead
tank, illustrating the concept of an on-off valve.

Among the valve types commonly employed for on/off service are ball, plug, butterfly
(or disk), gate, and globe valves. Particularly for larger on/off valves, their design is
crafted to ensure that the fully open position facilitates nearly unrestricted fluid flow.
This feature is exemplified by ball, plug, and gate valves, where complete openness
offers an unimpeded pathway for fluid movement. This design attribute is advantageous
for applications requiring rapid and unrestricted fluid conveyance, contributing to
efficient process operation.

On/Off Valve Characteristics:

• Employed in scenarios requiring frequent on-off operations.
• Chosen for processes demanding rapid and substantial flow changes, such as safety
systems or cooling water systems.

1. Frequent On-Off Service: Valves designed for frequent on-off service play a crucial
role in processes where the flow needs to be quickly started, stopped, or redirected
regularly. In industries like manufacturing, petrochemicals, and water treatment, there are
instances where fluid flow must be promptly initiated or halted. These valves are
constructed to withstand the wear and tear associated with repeated operations, ensuring
reliability and longevity. The frequent cycling might be related to maintenance, batch
processing, or emergency shut-offs.

2. Instantly Large Flow Needs: Certain industrial scenarios demand an immediate and
substantial surge in fluid flow. Safety systems, for instance, require rapid response
mechanisms to ensure the protection of personnel and equipment in case of emergencies.
Cooling water systems also fall into this category, where efficient cooling of equipment
or processes is paramount. The ability of these valves to provide a swift transition from
closed to fully open positions makes them invaluable in situations where delays in flow
adjustments could have severe consequences. Such valves are designed to handle quick
changes in flow rates without compromising performance or causing undue wear and
tear.
Equal Control Valve:
The Equal Control Valve plug exhibits a consistent percentage alteration in flow for each
predetermined unit of valve stroke, regardless of its position along the characteristic
curve. This design proves advantageous when the pressure differential across the valve
diminishes as the flow rate escalates. In scenarios of this nature, employing an equal
percentage control valve is recommended. To facilitate appropriate valve selection,
specialized sizing software plays a crucial role in identifying the ideal valve characteristic
for a given application. Moreover, equal control valves are particularly well-suited for
integration into control loops where the process gain diminishes in tandem with
heightened flow rates. By accommodating these variations, equal control valves
contribute to efficient and stable control performance in such dynamic systems.

Equal Percentage Characteristics:

• Employed in processes anticipating substantial fluctuations in pressure drop.
• Selected for control loops involving temperature and pressure regulation.

1. Large Changes in Pressure Drop: Linear control valves are a fitting choice for
processes characterized by significant variations in pressure drop. These valves are
capable of facilitating precise adjustments across a broad range of pressure differentials.
In situations where the pressure drop within a system can vary considerably due to
operational changes or external factors, linear control valves offer a reliable means of
maintaining control over the process. By correlating valve position with flow rate in a
linear manner, these valves allow for accurate management of pressure changes, ensuring
stability and efficiency in the system.

2. Temperature and Pressure Control Loops: Linear control valves play a pivotal role in
control loops designed to manage temperature and pressure. In many industrial and
manufacturing processes, maintaining consistent temperature and pressure levels is
paramount to achieving desired outcomes. Linear control valves provide a direct and
proportional relationship between valve position and flow rate, making them suitable for
precise adjustments required in temperature and pressure control. Whether it's
maintaining the temperature of a chemical reaction or controlling the pressure in a steam
system, linear control valves offer the responsiveness needed for accurate regulation.
Linear Control Valve:
Linear control valves, often referred to as multi-turn valves, are engineered with a
sliding-stem configuration that propels a closure element to either an open or closed state.
This particular construction gives rise to a proportional correlation between the valve's
position and the flow rate it regulates. As the valve stem's position adjusts, the flow
through a linear valve experiences a corresponding alteration. When visualized on
rectilinear coordinates, the connection between flow and valve travel approximates a
straight line, presenting a valuable characteristic. This distinctive property ensures that
equivalent adjustments in valve lift yield uniform volume changes, irrespective of the
percentage of valve opening. In practical terms, this means that the valve's behavior
maintains consistency across its operational range, allowing for precise and predictable
control of fluid flow.

Linear Valve Characteristics:

• Employed in control systems related to liquid level or flow regulation.
• Chosen for applications where a consistent pressure drop across the valve is anticipated.
• Opted for when the pressure drop across the valve constitutes a significant portion of
the overall pressure drop.

1. Liquid Level or Flow Loops: These valves find their utility in control loops that focus
on managing liquid levels or flow rates. For instance, in a water storage tank, a control
valve could be used to modulate the inflow or outflow, ensuring that the desired liquid
level is maintained. Similarly, in industrial processes involving the transportation of
fluids, linear control valves could be employed to regulate the flow rate, thereby
achieving precise control over the process.

2. Constant Pressure Drop: Linear control valves are particularly suited for situations
where the pressure drop across the valve needs to remain relatively stable. This might be
the case in systems where the downstream equipment or process requirements necessitate
a consistent pressure difference. The linear relationship between valve position and flow
rate allows for a predictable adjustment, ensuring that the pressure drop remains within
the desired range.

3. Significant Proportion of Pressure Drop: When the pressure drop across the valve
constitutes a notable fraction of the overall pressure drop in the system, linear control
valves can be advantageous. By providing a direct relationship between valve position
and flow rate, these valves enable effective management of the pressure drop within the
system. This becomes crucial in scenarios where maintaining specific pressure levels is
critical for the optimal functioning of downstream equipment or processes.

PROCEDURE:

1. Manipulate the hand valves to activate either the on/off, linear, or equal control valves.
2. Adjust the air regulator to achieve an output pressure of 15 PSI.
3. Power on the unit and optimize the pump speed to attain the maximum flow rate.
4. Fine-tune the hand valve to establish the highest achievable flow rate through the
control valve.
5. Record both the flow rate passing through the initially set rotameter value of 1000
liters per hour (l/h) and the corresponding stem position.
6. Systematically modify the air regulator's output in increments of 3, while measuring
the corresponding flow rates.
7. Repeat the procedures outlined in steps 5 and 6 for different pressure settings until the
rotameter readings reach zero. Tabulate the collected readings.
8. Repeat the comprehensive sequence from step 2 through step 7 for varying valve types,
and record the acquired data.
9. Construct graphical representations illustrating the relationship between stem position
and flow rate, utilizing the tabulated data for all three valve types.

This series of actions outlines the methodology for a systematic experimental

investigation of control valves' behaviors across different operational scenarios. The main
goal appears to be to analyze how different valves respond to varying pressures and how
this impacts flow rates. By sequentially adjusting variables, recording measurements, and
tabulating the data, the study aims to generate valuable insights into the control
characteristics of on/off, linear, and equal control valves. Additionally, the graphical
representation of stem position against flow rate will visually demonstrate the
performance nuances of each valve type under diverse conditions.

OBSERVATIONS:
On-Off Control Valve

Attenuation Pressure (Psi) Stem opening l (units) Flow Rate (L/hr) Line Pressure
3 0 0 13

6 0 0 13

7.5 1 450 10
8 2 750 4

9 4 950 1.5

12 11 1000 0

15 18 1050 0

Equal Control Valve

Attenuation Pressure (Psi) Stem opening l (units) Flow Rate (L/hr) Line Pressure

3 0 0 13

6 3 50 11
9 9 200 8

12 16 450 5

15 24 700 1
17.5 29 1000 0
 Linear Control Valve

Attenuation Pressure (Psi) Stem opening l (units) Flow Rate (L/hr) Line Pressure

3 0 0 13

6.5 1 100 11
7.5 3 250 8

9 7 500 5
12 13 850 2

15 22 1000 0
GRAPHS:
INFERENCES:
The plots presented above offer valuable insights into the behavior of different valve
types:

1. Linear Valve: The graphical representation demonstrates that a linear valve's flow
capacity displays a proportional increase as the stem opening expands. This means that as
the valve stem is adjusted incrementally, the flow rate adjusts in a direct and consistent
manner. Linear valves are particularly suited for scenarios where a steady and predictable
change in flow is desired based on incremental stem adjustments.

2. Equal Percentage Valve: The plots illustrate that an equal percentage valve showcases
an exponential relationship between flow capacity and stem opening. As the valve stem is
opened further, the flow rate increases at an escalating rate. This characteristic is
advantageous when managing processes that require finer control over flow rates at
higher positions of the stem, allowing for greater precision in regulating flow in scenarios
where finer adjustments are needed.

3. ON/OFF Control Valve: The depicted behavior of an ON/OFF control valve reveals
that it produces substantial changes in flow for even minor alterations in lift or valve
position. This characteristic is particularly valuable when abrupt flow changes are
essential, such as in safety systems or scenarios where fluid flow needs to be quickly
initiated or halted.

CONCLUSION:

Linear Valve Characteristics:

1. The flow passing through a linear valve exhibits a direct relationship with the position
of the valve stem. As the valve stem is adjusted, the flow rate changes proportionally.

2. When graphed, the resulting plot yields a straight line. This linearity signifies that
equal increments in lift, regardless of the percentage of valve opening, correspond to
uniform volume adjustments. This characteristic is advantageous when seeking precise
and predictable control over flow rates, as the valve's behavior remains consistent across
its operational range.
Equal Percentage Valve Characteristics:
1. The plotted data for equal percentage valves reveals that their plug induces the same
percentage change in flow for a fixed increment of valve stroke, irrespective of its
position on the characteristic curve. This feature underscores the valve's ability to offer
proportional adjustments in flow rate across its range, making it a valuable choice for
applications where fine control is essential.

Quick Opening Valve Characteristics:

1. The plot portraying quick opening valve behavior illustrates an initial steep slope. This
steep slope signifies that even a slight initial change in stem travel results in a substantial
increase in flow. This makes quick opening valves ideal for scenarios demanding swift
and significant flow adjustments.

2. Notably, the plotted curve reaches near-maximum flow levels relatively early in the
valve's lift range. This means that even with a relatively low stem lift percentage, these
valves achieve high flow rates, a characteristic particularly useful for rapid flow changes
in applications like emergency shut-offs or sudden surges in demand.

3. The steep slope observed in the initial linear region of the curve translates to a higher
initial gain, which can be advantageous for achieving quick and responsive flow rate
changes when the valve is initially opened.

REFERENCES:

1. Dale E. Seborg, Duncan A. Mellichamp, Thomas F. Edgar, Francis J. Doyle III -

Process Dynamics and Control-Wiley (2010)
2. InstrumentationTools.Com