CONTROL VALVE TECHNIQUE & TROUBLE SHOOTING
Why Attend
Course Objectives
Target Audience
Course Methodology
Why Attend
This course is designed to provide participants with an in-depth understanding of control valve technology, including the principles of operation, selection, installation, maintenance, and troubleshooting of control valves. The course aims to equip professionals with the necessary skills to ensure optimal performance and reliability of control valve systems in various industrial applications.
Course Objectives
Upon completing this Process Control Valves – Selection, Inspection and Maintenance course successfully, participants will have an understanding and know or be able to do after attending this course:
- To introduce the participant to different type of Control Valves.
- To familiarize the participant with the valve characteristics including the valve tightness class and the flow characteristics
- To upgrade the participants understanding of the application, operation and design of different types of valves
- To provide skills, knowledge and understanding of the principles and practices of the related Codes and Standards related to Control Valves
- To learn the methods for valve selection, specifications and sizing that suit a particular application
- To learn methods of valve testing, inspection and troubleshooting based on the industrial and manufacturer codes and standards.
- Control Valve defects, i.e. Travel deviations, Instrument Air defects, friction, flashing & Cavitation’s
- Control Valve Bench Set up
- Modern Control valve maintenance techniques. i.e. diagnostic, online monitoring, HART
Target Audience
Instrumentation and control engineers, Maintenance engineers and technicians, Process engineers, Operations supervisors.
Course Methodology
This interactive training course includes the following training methodologies as a percentage of total tuition hours :
- Lectures
- Workshops, work presentations ,
- Group Work in case study & Practical Exercises.
- Videos and general discussions
- Pre-Test and Post Test
Course Outline
Day - 1
Control Valve Terminology
- Control Valve
- Basic Control Loop
- Control Valve Gain
- Hysteresis
- Dead Band (Backlash)
- Hysteresis & Dead Band Effects
- Linearity
- Rangeability
- Turndown
- Accuracy
- Repeatability
- Loop Gain
- Resolution
- Dead Time
- Capacity (Valve)
- Friction
- Stiction
- Principles Of Valve Throttling Processes
CONTROL VALVE STANDARDS:
- Well Known Valve Standards
- Instrument Society of America (ISA)
- ANSI -American National Standards Institute
- API – American Petroleum Institute
- ASME-American Society of Mechanical Engineers
- NACE-National Association of Corrosion Engineers
Day - 2
CONTROL VALVE COMPONENTS- CONTROL VALVE BODY:
- Basic Valve Components- Body- Bonnet- Trim (Plug and Seat)- Packing- Actuator- End Connections
- Control Valve Classification
- Linear (Sliding Stem Valves)
- Globe Valves
- Single-Ported Globe
- Double-Ported Globe Valve
- Application-Throttling general purpose flow control valve
- 3-Way Valves
- Angle Valves
- Z Globe Valve
- Y Globe Valve
- Diaphragm Valve- Diaphragm Valve Assembly-Diaphragm Valve Positions (On-Off)-DIAPHRAGM VALVE POSITIONS (THROTTLING)-Application-Used for Biochemical Processes and For Regulation Of Most Gases And Liquids
- Gate Valve-Rising and Non-Rising Stem-Gate Valve with Handwheel- Application-stop valves, (not throttling), high pressure and temp, not for slurries, viscous fluids
- Knife Gate valve
- Rotary Valves
- Ball Valve-Ball Valves Open / Close States-Application-Flow Control, Pressure Control, Shutoff, Corrosive Fluids, Liquids Gases, High Temperature
- Butterfly Valves-Butterfly Positions-Application-Low Pressure, Large Diameter Lines Where Leakage Is Unimportant
- Disc Valve
Day - 3
CONTROL VALVE BODY SELECTION/ CONTROL VALVE PACKING:
- Globe (Plug and Seat)
- Butterfly
- Diaphragm / Pinch
- Ball
- What Is Packing?
- Packing In Sliding Stem Valve
- Stationary Loading
- Live-Loaded Valve Stem Packing
- Adjusting Packing Assemble
- Packing Material Selection
- Typical Packing Arrangement
- Typical Packing Friction Values
- Packing Material Specification
- Shutoff Classes
- Valve Seat Leakage
- Valve Leakage Classifications
CONTROL VALVE ACTUATORS:
- Actuators
- Pneumatic Actuators
- Diaphragm Actuators-Diaphragm Actuators Assembly
- Piston Actuators
- Double Acting Piston
- Rotating Actuators (Rack-And Pinion Mechanism)
- Hydraulic Actuators-Examples
- Electric Actuators (Mov)
- Hand Actuators
- Self-Actuated Valves
- Self-Operated, Spring-Loaded Gas Pressure Regulating Valve
- Pilot-Loaded or Externally-Loaded Pressure Regulator
- Actuator Types Symbols
Day - 4
VALVE FAILURE MODES/ ACTUATOR BENCH-SET/ACTUATOR RESPONSE:
- What is the meaning Failure?
- Direct/Reverse actions
- Direct Body
- Reverse Body
- Failure modes Symbols
- How to select failure mode for a control valve
- Introduction
- Bench-Set Adjust-cases
- Actuator response problem
- 1st Using I/P transducer-I/P transducer
- 2nd Using Volume booster
- Volume booster VS Pressure regulator
CONTROL VALVE POSITIONER/ SPLIT RANGE CONTROL/CONTROL VALVE CHARACTERIZATION:
- Why do we need a positioner?
- Positioner is a control system.
- Advantages of adding positioner
- How can Positioner increase valve seating
- Electronic positioners (Flowserve 3200 MD Smart Positioner)
- Examples for electronic and Pneumatic positioner
- Split range Control
- Complementary valve sequencing
- Exclusive valve sequencing
- Progressive valve sequencing
- Inherent versus installed characteristics
- Installed characteristics
- Solving linearity problems
- Ideal Characteristic curves
- Examples
- Modified characteristic curves
- Practical Characteristic curves from manufacturers data
- Valve trim Assignments
- Cage guided
- Ball valve trim
Day - 5
CONTROL VALVE ENGINEERING PROBLEMS/3-term Controllers and Loop-tuning for Processes containing Control Valves:
- Stiction
- How stiction affect valve movement
- Flashing-What is flashing?
- Effect of valve body on flashing
- Cavitation
- Preventing flashing
- Use cavitation-control valve trim
- Special trim design
- Ball valve special trim
- Cushion with introduced gas
- Sustain the flashing action
- Chocked flow
- Flow vs ΔP
- Noise Prediction Aerodynamics
- Pressure drops staging
- Flow division
- Special valve trim
- Path control
- Erosion
- Bonnet damage
- Corrosion
- Valves, and how they fit into pressure relief and Safety Instrumented Systems (SIS)
- Using digital controllers, with valves
- Understanding & implementing the right controller action, for fail-safe valves
- Understanding all of the variables, associated with three-term control
- Open loop tuning, for controllers that act on control valve loops
- Closed loop tuning, for controllers that act on control valve loops
- Trial and error tuning, to optimize control valve performance
Using Valves in Cascade, Ratio, Dead-Time Dominant, Non-Linear & PLC-Controlled Processes/ Installation and Maintenance:
- Setting up a cascade loop, using a single valve and multiple controllers
- Setting up a ratio loop, using a single valve and multiple process variables (PVs)
- Dead time dominant loops, how this affects the valve performance, and how this is corrected
- Using a control valve in a process that exhibits different responses in different zones
- Combining PLCs, for valve control
- Proper Storage and Protection
- Proper Installation Techniques
- Use Good Piping Practices
- summary