APPLICATIONS

Key applications of a control station assembly in piping include:

1) FLOW CONTROL VALVES

Maintaining a specific flow rate of a fluid in a pipeline by adjusting the valve opening based on demand.
Flow control valves are used to regulate the flow of fluids. Control of flow in hydraulic systems is critical
because the rate of movement of fluid-powered machines or actuators depends on the rate of flow of
the pressurized fluid

Flow control valves come in all shapes, sizes, and designs. Their basic function, however, is the same—to
control flow of air. Flow control valves for hydraulic systems (liquids under pressure) are of the same
basic design. A typical example of a flow control valve is the simple water faucet installed in homes.

Globe valves and needle valves are standard designs used for flow control. Unidirectional flow control
valves control the flow in one direction but permit free flow in the other direction. Pressure-
compensated flow control valves are also manufactured. These valves control the amount of flow and
will maintain a constant flow at different pressures. These valves are ideal for some applications but
should be used only when required because of their higher cost.

The check valve is another type of flow control valve. The function of a check valve is to permit flow in
only one direction. A very common function of flow control valves is to control the speed of cylinders
and air motors. The speed of cylinders or air motors depends on the amount of air, which can be
controlled by flow control valves.

VALVE CLASSIFICATIONS

Valves are classified by their intended use: flow control, pressure control, and direction control. Some
valves have multiple functions that fall into more than one classification.

Ball Valves

Ball valves are shutoff valves that use a ball to stop or start the flow of fluid downstream of the valve.
The ball, shown in Figure 7-1, performs the same function as the disc in other valves. As the valve handle
is turned to open the valve, the ball rotates to a point where part or the entire hole that is machined
through the ball is in line with the valve body inlet and outlet. This allows fluid flow to pass through the
valve. When the ball is rotated so that the hole is perpendicular to the flow path, the flow stops.

Sign in to download full-size image

Figure 7-1. Typical ball valve.

Most ball valves are the quick-acting type. They require a 90-degree turn of the actuator lever to either
fully open or completely close the valve. This feature, coupled with the turbulent flow generated when
the ball opening is partially open, limits the use of ball valves as a flow control device. This type of valve
is normally limited to strictly an “on–of” control function.

Gate Valves

Gate valves are used when a straight-line flow of fluid and minimum flow restriction are needed. Gate
valves use a sliding plate within the valve body to stop, limit, or permit full flow of fluids through the
valve. The gate is usually wedge-shaped. When the valve is wide open, the gate is fully drawn into the
valve bonnet. This leaves the flow passage through the valve fully open with no flow restrictions.
Therefore, there is little or no pressure drop or flow restriction through the valve.

Gate valves are not suitable for throttling volume. The control of flow is difficult because of the valve's
design and the flow of fluid slapping against a partially open gate can cause extensive damage to the
valve. Except as specifically authorized by the manufacturer, gate valves should not be used for
throttling.

Gate valves are classified as either rising-stem or non-rising-stem valves. The non-rising-stem valve is
shown in Figure 7-2. The stem is threaded into the gate. As the handwheel on the stem is rotated, the
gate travels up or down the stem on the threads while the stem remains vertically stationary. This type
of valve will almost always have a pointer indicator threaded onto the upper end of the stem to indicate
the position of the gate.

Sign in to download full-size image

Figure 7-2. Operation of agate valve.

Valves with rising stems (Figure 7-3), are used when it is important to know by immediate inspection
whether the valve is open or closed or when the threads exposed to the fluid could become damaged by
fluid contamination. In this valve, the stem rises out of the valve bonnet when the valve is opened.
Sign in to download full-size image

Figure 7-3. Rising stem gate valve.

Globe Valves

Globe valves are probably the most common valves in existence. The globe valve gets its name from the
globular shape of the valve body. Other types of valves may also have globular bodies. Thus, it is the
internal structure of the valve that defines the type of valve.

The inlet and outlet openings for globe valves are arranged in a way to satisfy the flow requirements.
Figure 7-4 shows straight-, angle-, and cross-flow valves.

Sign in to download full-size image

Figure 7-4. Types of globe valves.

The part of the globe valve that controls flow is the disc, which is attached to the valve stem. Turning the
valve stem in until the disc is seated into the valve seat closes the valve. This prevents fluid from flowing
through the valve (Figure 7-5, view A). The edge of the disc and the seat are very accurately machined so
that they form a tight seal when the valve is closed. When the valve is open (Figure 7-5, view B), the fluid
flows through the space between the edge of the disc and the seat. Since the fluid flow is equal on all
sides of the center of support when the valve is open, there is no unbalanced pressure on the disc that
would cause uneven wear. The rate at which fluid flows through the valve is regulated by the position of
the disc in relation to the valve seat. This type of valve is commonly used as a fully open or fully closed
valve, but it may be used as a throttling valve. However, since the seating surface is a relatively large
area, it is not suitable for a throttling valve where fine adjustment is required.

Sign in to download full-size image

Figure 7-5. Operation of a globe valve.

The globe valve should never be jammed in the open position. After a valve is fully opened, the
handwheel or actuating handle should be turned toward the closed position approximately one-half
turn. Unless this is done, the valve is likely to seize in the open position, making it difficult, if not
impossible, to close the valve. Many valves are damaged in this manner. Another reason for not leaving
globe valves in the fully open position is that it is sometimes difficult to determine if the valve is open or
closed. If the valve is jammed in the open position, the stem may be damaged or broken by someone
who thinks the valve is closed.

It is important that globe valves be installed with the pressure against the face of the disc to keep the
system pressure away from the stem packing when the valve is shut.

Needle Valves

Needle valves are similar in design and operation to globe valves. Instead of a disc, a needle valve has a
long tapered point at the end of the valve stem. Figure 7-6 shows a cross-sectional view of a needle
valve.

Sign in to download full-size image

Figure 7-6. Cross-section of needle valve.

The long taper of the valve element permits a much smaller seating surface area than that of the globe
valve. Therefore, the needle valve is more suitable as a throttling valve. Needle valves are used to
control flow into delicate gauges, which might be damaged by sudden surges of fluid flow under
pressure.

Needle valves are also used to control the end of a work cycle, where it is desirable for motion to be
brought slowly to a halt, and at other points where precise adjustments of flow rate are necessary and
where a small rate of flow is desired.
Although many of the needle valves used in fluid power systems are the manually operated types
(Figure 7-6), modifications of this type of valve are often used as variable restrictors. This valve is
constructed without a handwheel and is adjusted to provide a specific rate of flow. This rate of flow will
provide a desired time of operation for a particular subsystem. Since this type of valve can be adjusted
to conform to the requirements of a particular system, it can be used in a variety of systems. Figure 7-7
illustrates a needle valve that was modified as a variable restrictor.