Reliance Industries Ltd.

Jamnagar

The Boss of Control

Loop,
Final Control Element
1

Reliance Industries Ltd.

Jamnagar

CONTROL VALVE
AN OVERVIEW
2

TODAYS DISCUSSION
CONTENT WHAT IS A CONTROL VALVE ?
CONTROL VALVE ACTUATOR & ACCESSORIES
STANDARDS APPLICABLE FOR CONTROL VALVE
FLASHING
CAVITATION
CONTROL VALVE SELECTION & INTERCHANGEABILITY
VALVE GLAND PACKING & MATERIAL OF CONSTRUCTION
CONTROL VALVE LEAKAGE CLASS
CONTROL VALVE CHARACTERISTICS
ARDUOUS SERVICE VALVE
3
NOISE REDUCTIONS PRACTICES

WHAT IS A CONTROL VALVE

?
CONTROL VALVE
This is a device used to modulate flow of process fluid in
line by creating a variable pressure drop in the line .
Normally the pressure drop is made with respect to the
control signal received towards flow condition correction
required.

WHAT IS VALVE FLOW COEFFICIENT ?

VALVE Cv - No. Of US gallon [ USG = 3.7 Ltrs] of water per
minute passing through the valve in full open condition
with 1 PSI pressure Drop across the valve at 15 deg C
temp.
So essentially valve Cv is capacity of valve in terms of
water which helps us to identify suitable size required for
any fluid in any pressure / temp. condition.
VALVE Kv - Quantity of water in M3/Hr. at temperature
between 5 to 40C that will flow through the valve at a
specified travel with a pressure drop of 1 Bar.
Kv = 0.856Cv
5

TYPE OF CONTROL VALVE

All Control valve can be divided in two category.
1. Sliding stem ( Globe valve)
2. Rotary shaft
( Quarter turn )
Also valves may be further subdivided as shown below
BY SHAPE
GUIDING

BY INTERNAL

GLOBE

BY CHAR.

PLUG

EQ%

BY
TOP

SINGLE SEAT
DOUBLE SEAT
BUTTERFLY

CAGE

LINEAR

CAGE

ANGLE

FULL BALL QUICK OPEN TOP & BOTTOM

SLANT

SLEEVED

PARABOLIC
BUSH/BEARING
6

VALVE ACTUATOR

Actuator - Mechanism which

operates the valve by
receiving the control signal.

Type of Actuator
Pneumatic - Spring Diaphragm
Piston Cylinder
Electrical - Not discussed
Hydraulic- Not discussed

VALVE ACTUATOR

VALVE ACTUATOR

CONTROL VALVE STANDARDS

ANSI :- AMERICAN NATIONAL STANDARDS INSTITUTE
B16.34 :- STEEL VALVES
DEFINES CRITERIA FOR VALVE WALL THICKNESS REQUIREMENTS
DEFINES PRESSURE / TEMPERATURE RATINGS
DEFINE HYDRO-TEST REQUIREMENTS
Example :A351 CF8M ( Material :- 316SST; Temp range :- -425 F to 1500 F)
A216 WCB ( Material :- Carbon Steel; Temp range:- -20 F to 1000 F )
B16.37 :- HYDROSTATIC TEST PROCEDURE
DEFINES REQUIREMENT FOR HYDRO-TEST = 1.5 X MWP
MWP = MAXIMUM WORKING PRESSURE
B16.104 :- CONTROL VALVE SEAT LEAKAGE CLASSIFICATION
ESTABLISHES TEST PROCEDURES AND SEAT LEAKAGE CLASSES
API :- AMERICAN PETROLEUM INSTITUTE
SPEC 6B :- DEFINES PIPELINE VALVE
SPEC 600 :- STEEL GAGE VALVES, FLANGED BUTT WELDING ENDS

10

VALVE ACCESSORIES

VALVE POSITIONERS
PNEUMATIC
ELECTRONEUMATIC
SMART DIGITAL
PROXIMITY SWITCHES
INDUCTIVE TYPE
PNEUMATIC CAM OPERATED
SOLENOID VALVES
LATCHING/ NON-LATCHING
WITH MANUAL OVERRIDE
SIGNAL BOOSTERS
PRESSURE
VOLUME
SIGNAL INVERTERS
HANDWHEEL
AIR VOLUME TANK

11

CONTROL VALVE STANDARDS

NACE :- NATIONAL ASSOCIATION OF CORROSION ENGINEERS
NACE MR-01-75
DEFINES SULFIDE STRESS CRACKING RESISTANCE MATERIAL
MATERIAL COMPLY TO NACE STANDARD ARE
CARBON STEEL WITH HEAT TREATMENT
SST 302,304,316,17-4PH
ALLOY STEEL MONEY, HASTELLOY C
MATERIAL NOT SUITABLE FOR NACE ENVIRONMENT IS
CAST IRON

12

CONTROL VALVE STANDARDS

ISA :- INSTRUMENT SOCIETY OF AMERICA
DEFINES STANDARDS FOR CONTROL INDUSTRY
Example :VALVE SIZING EQUATIONS.
NOISE PREDICTION TECHNIQUE
CONTROL SIGNAL 3 - 15 PSIG, 6 - 30 PSIG

OSHA :- OCCUPATIONAL SAFETY AND HEALTH ACT

DEFINES CRITERIA FOR PERMISSIBLE DURATION FOR EXPOSURE OF NOISE LEVEL

13

SHELL REFERENCES

Control Valves Selection , Sizing and

Specification
DEP 32.36.01.17- Gen July 1987 &
Basic Process control & Instrumentation
Shell M114-1999
Shell Best Practice [Ref Process
Measurement and Control Devices Shell
Canada Ltd Standard 16-1.2]

14

CONTROL VALVE LEAKAGE

Control Valve Leakage This is basically the fluid which passes through the valve
when the valve is fully closed. This value however should
not be considered as the valve Cv at NIL Opening.
So this leakage shall depend on the contact of valve plug &
seat with the seating force applied for holding the plug over
the seat.

15

CONTROL VALVE LEAKAGE

Maximum Leakage
ANSI/FCI 70-2
Test Medium
0.5% valve capacity at full travel
Class II
0.1% valve capacity at full travel
Water / Air
Class III
0.01% valve capacity at full travel
Class IV
0.0005ml/min/psid/in. port dia
Class V
Water
Bubbles per
Port dia.
mL per Min.
Min.

Class VI

1
1 - 1/2
2
2 - 1/2
3
4
6
8

1
2
3
4
6
11
27
45

0.15
0.30
0.45
0.60
0.90
1.70
4.00
6.75

Air

16

Pressure and temperature

Service DP or 50 PSID
whichever is lower at 10 to
52deg C
Service DP at 10 to 52deg C

Service DP or 50 PSID
whichever is lower at 10 to
52deg C

VALVE CHARACTERISTICS
Equal % - Rate of change of flow due to
change of valve
travel is
proportional to earlier flow.
Linear
to rate of
travel

- Rate of change of flow is same

change of valve

Quick Open
change of

- Full capacity attaining without

travel after initial opening

On/Of
- Used mainly as Isolation valves
17
(Pump suction
and ESD valves)

TRIM AND CAGE DESIGN

1. CHARACTERISING FLOW
Linear Cage
Quick Opening Cage
Equal Percentage Cage
Modified Equal percentage flow
2. NOISE ABATEMENT
3. ANTI CAVITATION

18

CHARACTERIZING FLOW BY CAGE

TYPE

19

CHARACTERIZING FLOW
100
Quick
Opening

Li

Cv
%
Design Cv

80

ar
e
n

60
40
20
a
Equ

l%

0
0

20

40
60
80
% Valve Travel
20

100

VALVE SELECTION PROCESS FOLLOWED

IN RELIANCE
If valve sizing does not give warning of cavitation, flashing or Noise level (
>85dBA) then select standard trim valve.
If valve sizing gives warning of cavitation, flashing or Noise level ( >85dBA)
then select arduous service trim valve.
Example:For cavitation select CAVITROL III stage 1 to 5 valve or
CAVITROL 4 valve.
For noise select WHISPER I ,III or WHISPERFLO valve trim.
Select the suitable Approved vendor suiting the product .
Example:- ABB - Introl design or CCI - DRAG design.
In case of very high DP ( DP*100/P1 > 50%) or Noise select ABB or CCI
valves.
Example:- Compressor Anti - surge control valves - CCI- DRAG design.

21

VALVE SELECTION PROCESS

S ta n d a rd M a te ria ls :
C a rb o n s te e l W C B
C a rb o n s te e l N A C E
S ta in le s s s t e e l 3 1 6 o r 3 1 6 L

S ta n d a rd R a tin g s :
A N S I r a tin g c la s s 1 5 0
A N S I r a tin g c la s s 3 0 0
A N S I r a tin g c la s s 6 0 0

Is it
s ta n d a a r d
m a te ria l

No

Yes

Is it s ta n d a r d
fla n g e r a tin g

No

Yes

S p e c ia l v a lv e d e s ig n
a n d a p p lic a tio n
re f D E P 3 2 .3 6 .0 1 .1 7

S ta n d a rd T e m p . R a n g g e
0 deg. C
+ 420 deg. C

Is
te m p e r a tu r e
w ith in g
s ta n d a rd
ra n g e
Yes

No

S e v e re S e rv ic e :
C h o k e F lo w
C a v ita tio n
N o is e a b o v e 8 5 d b A
O x y g e n s e r v ic e

Is it s e v e r
s e r v ic e

L o w te m p e r a tu re s e r v ic e
H F s e r v ic e
E th y le n e o x id e s e r v ic e
V a c u u m s e r v ic e
H P s t e a m s e r v ic e
H y d r o g e n s e r v ic e
C h lo r in e s e r v ic e

Y es

No

S ta n d a r d v a lv e d e s ig n
a n d a p p lic a t io n .
R e f D E P 3 2 .3 6 .0 1 .1 7
A ll S e c tio n e x c e p t 6
and 7

22

POPULATION OF CONTROL VALVES AT

RELIANCE JAMNAGAR.
Based on above criteria RIL complex has following
Installed quantity of valve

Fisher direct supply ( Through Bechtel ) :1800+ valves.

Fisher package supply valves :800+
Masoneilan package supply : 180 +
ABB UK direct supply :150+
CCI USA direct supply :40+
Fisher Gulde package supply : 190 +
Linde Mepag package supply : 120 +
Copes Vulcan package supply : 50 +
Keystone Biffi direct supply : 300 +
Neles Jamesbury direct supply
23 : 630 +

VALVE INTERCHANGEABILITY
Body pressure rating and certification ( e.g. IBR )
End connection ( Ex:- Screwed or welded flange connection )
Valve Size and type.
Trim Size - Cv
Leakage classification
Body and trim material and certification ( e.g. NACE )
Plug and cage characteristics.
Actuator bench setting / spring range.
Actuator action ( AFC/ AFO )
Process temperature ( For gland packing and body - trim material )

24

Flow Path through a Control Valve - Analogy

Minimum
Geometrical
Flow Area

Streamlines Contract as
Flow Approaches Restriction
25

Vena Contracta
(Minimum Flow Area)

Variation in Pressure and Velocity

P1
Pressure
Variation

Velocity
Variation

P2

Valve
Outlet

Valve
Trim
Inlet Trim Exit Vena
Inlet
Contracta
26

Pressure Recovery

P
Low
Recovery
High
Recovery
Valve
Outlet

Valve
Trim
Inlet Trim Exit Vena
Inlet
Contracta
27

FLASHING
Flashing :
The formation of vapor bubbles in liquid flow streams at vena
contracta.
As liquid passes through a restriction (vena contracta) in a control valve the
liquid velocity increases and liquid pressure decreases. And if the pressure at this
point falls to or below the vapor pressure of the liquid, vapor bubbles form in the
flow stream. Flashing results if this pressure remains below vapor pressure of
liquid.
When a liquid flashes into vapor, there is a large increase in volume. Due to
increase in volume velocity will increase and hence high velocity will erode the
surface.
Flashing damages can be identified by smooth polished appearance of eroded
surface. Flashing damages is usually at or near seat line of the valve plug and
seat ring.
28

Vapor pressure :- The pressure at which liquid begins to vaporize.

FLASHING DAMAGE ( Tag no. 241FV040

)

29

FLASHING DAMAGE ( Tag no. 241FV040

)

30

CAVITATION
Cavitation : The formation and subsequent collapse of vapor bubbles in
liquid flow streams.
As liquid passes through a restriction in a control valve the liquid velocity
increases, while the liquid pressure decreases. The pressure reaches a minimum
at a point called the vena contracta, and if the pressure at this point falls to or
below the vapor pressure of the liquid, vapor bubbles form in the flow stream.
Downstream of the vena contracta, flow area increases, velocity de-creases, and
pressure increases.
If this recovered pressure is sufficient to raise the pressure above the liquid
vapor pressure, the vapor bubbles will collapse. The collapsing bubbles generate
significant noise and vibration, and can mechanically attack pipe walls and valve
components.
Cavitation damages can be identified by rough and pitted surface. Cavitation
damage may extend to the downstream pipeline if that is where the pressure
recovery occurs.
31
Phenomenon of Cavitation is experienced in CV and PUMPS

CAVITATION
P1

P2
PV
PVC
Valve
Outlet

Valve
Trim
Inlet Trim Exit Vena
Inlet
Contracta
32

CAVITATION DAMAGE

33

CAVITATION CONTROLS
SYSTEM DESIGN
1. LOCATION OF VALVE
2. CASCADING
MATERIAL SELECTION
HARDEN MATERIAL,
LIKE 17-4 pH, 440C, 420SST HT
AND 316/COLMONOY 6 / ALLOY 6

34

CAVITATION CONTROLS
ANTI - CAVITATION PRODUCTS
CCI DRAG DESIGN, UP TO 380 BAR PRESS. DROP.
FISHER CAVITROL - III DESIGN
CAVITROL - III WITH 1 STAGE- UP TO 99 BAR.
CAVITROL - III 2-3 STAGES- 99 TO 207 BAR.
CAVITROL -4 , ABOVE 200 BAR, SIZE LIMIT 2 TO
6.
ABB INTROL DESIGN

35

CAVITATION CONTROLS :- FISHER

CAVITROL DESIGN

CAVITROL - III

CAVITROL - III

STAGE - 2

STAGE - 3
36

CAVITATION CONTROLS :- FISHER

CAVITROL DESIGN

CAVITROL - 4

37

CAVITATION CONTROLS :- ABB INTROL

DESIGN

INTROL CAGE

38

CAVITATION CONTROLS :- CCI DRAG

DESIGN

CCI DRAG CAGE

39

CAVITATION CONTROLS :- CCI DRAG

DESIGN

40

CAVITATION CONTROLS :- CCI DRAG

DESIGN

41

CHOKED FLOW

Choked flow :Formation of vapour bubbles in the liquid flow stream cause
a crowding condition at the vena contracta which tends to
limit flow through the valve.
If valve pressure drop is increased slightly beyond
the point where bubbles begins to form, a choked flow
condition is reached. With constant upstream pressure,
further increase in pressure drop will not produced
increased flow through the valve.

42

NOISE FUNDAMENTALS
Noise :- A random mixture of sound pressure waves of various amplitudes and
frequency. Which people do not like to hear.
Sound Wave :- A pressure wave with a fixed frequency and amplitude traveling
through a medium.
Unit of Noise :- dBA ( Decibels )= 20 Log( Existing sound pressure level / 0.0002
microbars )
Source of valve noise:
Mechanical Noise :- It produces high mechanical stress - fatigue failure of
vibrating part.
Mechanical noise can be solved by
improved design to suppress vibration by
good guiding
and rugged construction.
Vibration of valve components :- This is due to lateral movement of
valve plug relative to guide surfaces. The sound level produce normally
will have frequency less then 1500Hz and is describe as metallic
rattling.
Fluid impingement upon the movable of flexible part ( Metallic
chattering )
Components resonates at its own natural frequency ( single tone
43
3KHz to 7KHz)

NOISE FUNDAMENTALS
Aerodynamic Noise :Highest energy component at same frequency where human ear is most
sensitive. Large amount of energy converted to aerodynamic noise.
High intensity noise resulting due to turbulent flow of gas, are due to
high relative velocity.
This can be classified as non-periodic or random noise with occurring
frequency between
1 KHz to 8 KHz.
Valve pressure drop ( Main source ),
Obstruction in flow path,
Valve style , having more flow directional changes,
Degree of turbulence varies with valve style1,
Valve size.
44

PERMISSIBLE EXPOSURE DURATIONS NOISE

LEVEL
OSHA :- OCCUPATIONAL SAFETY AND HEALTH ACT
DEFINES CRITERIA FOR PERMISSIBLE EXPOSURE DURATIONS NOISE LEVEL
IN JAMNAGAR COMPLEX MAX. 85 dBA IS CONSIDERED AS A VALVE SELECTION
CRITERIA.

DURATIO N IN HO URS PER DAY

SO UND LEVEL IN DBA

90

92

95

97

100

1-1/2

102

105

1/2

110

1/4 O R LESS

115
45

NOISE CONTROL
PATH TREATMENT
INSULATION OF PIPE
HEAVY WALLED PIPE
SILENCER
SOURCE TREATMENT
VALVE CAGE STYLE ( TRIM )
WHISPER - I ( DP/P1 <= 0.65 ), Noise reduction up to 18 dBA.
WHISPER - III ( 0.6 <= DP/P1 <= 0.99 ), Noise reduction up to 30
dBA.
WHISPERFLO (NEW DESIGN), Noise reduction up to 10 dBA.
BY INLINE DIFFUSER
BY WHISPER DISK

46

NOISE CONTROL - SOURCE TREATMENT

WHISPER - III DESIGN

WHISPER - I DESIGN

47

NOISE CONTROL - SOURCE TREATMENT

WHISPERFLO DESIGN BY FISHER

48

NOISE CONTROL - SOURCE TREATMENT

WHISPER DISK AND

IN LINE DIFFUSER
DESIGN BY FISHER

49

NOISE CALCULATION
SPL = SPLP + SPLCG + SPLP/P1 + SPLK +

SPLP2

SPL = OVERALL NOISE LEVEL IN DECIBLE ( 1 METER DOWNSTREAM OF VALVE

OUTLET AND 1METER FROM THE PIPE SURFACE )
SPLP = FUNCTION OF PRESSURE DROP ACROSS THE VALVE ( MAJOR
COMPONENT )
SPLCG = GAS SIZING COEFFICIENT ( MAJOR COMPONENT )
SPLP/P1 = RATIO OF PRESSURE DIFFERENTIAL TO INLET PRESSURE
SPLK = CORRECTION IN DBA FOR PIPE SIZE AND SCHEDULE
SPLP2 = DOWNSTREAM PRESSURE
SIMPLIFIED EQUATION ( WITHOUT MUCH LOSS OF ACCURACY ) :
SPL = SPLP + SPLCG

50

CONTROL VALVE GLAND PACKING

51

CONTROL VALVE GLAND PACKING

Temp.
Range

Common use

-73 to 232C

Non-Radioactive

-40 to 232C

All chemicals ( Except

Molten alkali) Non
radioactive
Vacuum Pressure /
Vacuum

Suitablity
for Oxygen
/Oxidizing
Service

Packing material

Description

Stem
friction

Split rings of braided

composition impregented with Low
PTFE

Yes

PTFE impregented
composition

No

single PTFE V - Ring Solid rings of molded PTFE

Low

No

Double PTFE V - Ring Solid rings of molded PTFE

Low

Special
consideration

Required 2 to 4
micro inch RMS
valve plug stem
finish

Split rings of braided,

preshrunk PTFE yarn
impregented with PTFE;
available with copper rings at
Low
top and bottom of packing
box to meet UOP
specification 6-14-0 for acid
service.

-84 to 232C

Vacuum, All chemicals

Yes
( Except molten alkali )

-18 to 538C

Water, Stem Petroleum

products, Radiactive
Yes but upto Graphite/
and Non-radiactive
371C
Ribbon/Filament
nuclear

Ribbon style graphite rings

and rings of braided graphite
fibers with sacrificial zinc
washer

High

Low chloride
content ( less then
100ppm) chrome
plated stem not
necessary for high
temperature service

371 to 649C

High temperature
oxidizing service

Solid rings of ribbon-style

graphite with sacrificial zinc
washers

High

Yes

Chesterton 324

Ribbon - Style
graphite

52

VALVE MATERIAL
Essentially material for the valve is valve assembly MOC.
Standard material commonly used can be listed as below Valve Body & Bonnet
- As per Process
Internals
- As per Process . Commonly SS316
with or w/o
stellite.
Valve Gasket
- Graphite, Metallic SS 316 or SS
316L
Valve Packing
- Commonly Teflon Or Graphite
Fasteners
- B7 or B8M
Actuator Yoke
- Cast Iron
Actuator Spring - Spring Steel
Actuator Diaphragm
- Nitrile Rubber with fabric
reinforcement
Accessories
- Commonly Aluminum.
53

TECHNOLOGY
With the advent of new technology Control
Valve has undergone rapid change in terms of
change in Internals, Capacity Increase,
Guiding, Leakage Class Improvement,
Treatment of Noise And Cavitation And Finally
DIGITAL.
About 30 years back control valves were only
available with top guided or top & bottom
guided design with asbestos packing and
practically no solution available for Hi
Pressure drop application leading to Noise for
Gas service Or Cavitation54for Liquid Service.

TECHNOLOGY
Now a days we are also having control valve with digital
technology, where valve positioner is digital in nature
and able to provide PID function at the valve itself.
Digital positioner can provide the following apart from
acting as interface between controller and valve actuator
1. Provide HART feedback.
2. Can couple with Foundation Fieldbus.
3. Can provide valve diagnostics.
4. Helps in Asset Management.
5. Provide lock, soft alarms and data logging facilities.
6. Can achieve split action, remote calibration etc.

55

Trouble Shooting in Control Valves.

T R O U B L E S H O O T IN G
M A L F U N C T IO N
LEA KAG E

A C T IO N
C Y C L IC M O T IO N

IN S T A B IL IT Y

H U N T IN G
( A t a n y v lv o p e n in g )
H ig h S t e m F r ic t io n

V IB R A T IO N (N O IS E )

H U N T IN G
( N e a r t o v lv c lo s e p o s n )
O v e r s iz in g

To C heck
G la n d P a c k in g

R educe dP

In c re a s e
A c tu a to r

U s e S m a lle r
C v v a lv e

F lo w t o C lo s e
flo w d ir e c t io n

C hange
F lo w d ir .

A t a n y v lv
o p e n in g
In c re s e
S u p p o rt

O th e r
s o u rc e

F in d

P lu g g u id e
w e a r & te a r

R e p la c e
w ith n e w

56

D U LL R ES PO N SE

N O T W O R K IN G

A t s p e c ific
v lv o p e n in g

P oor
P ip in g

C h e c k V lv
G u id in g

O TH ER S

R esonance of
V ib r a t io n

R esonance
N o is e
o f v lv p lu g

In c re a s e
p ip e s u p p o r t

C hange
p lu g
p r o file

T h r o t le p u m p
d is c h a r g e
v a lv e

C hange
C v v a lu e

Trouble Shooting in Control Valves.

T r o u b le S h o o t in g

M A L F U N C T IO N

C Y C L IC M O T IO N

A C T IO N

LE AKA G E

O THER S

D U LL R E SPO N SE

N O T W O R K IN G

T ra v e l N o t
s m o o th
( I n b o t h d ir )

S lu r r y / s lu d g e
in v lv g u id e

A c tu a to r
p is t o n r in g
w e a r & te a r

C hange
P is t o n r in g

T ra v e l N o t
s m o o th
( I n o n e d ir )

G la n d p k g
h a rd e n e d

L e a k in
A c tu a to r
d ia p h .

C hange
g la n d p k g

C hange
d ia p h .

D is s e m b le &
C le a n

L e a k fro m
A c t. s te m
seal
C hange
s te m s e a l

U se dust
s e a l b e llo w

E n la r g e
g u id e r in g
b le e d e r h o le
P r o v id e
fla s h in g p o r t

U s e ja c k e t e d
v lv b o d y

U s e ro ta ry
o r a n g le t y p e
v a lv e

57

Trouble Shooting in Control Valves.

T r o u b le S h o o t in g

M A L F U N C T IO N

C Y C L IC M O T IO N

N o s ig n a l &
s u p p ly p r .

A C T IO N

LE AKA G E

D U LL RE SPO N S E

N O T W O R K IN G

N o s ig n a l p r .
s u p p r. a v l

O TH ER S

N o s u p . p r.
S ig n a l p r . a v l

P o s n O / P N il

A c tu a to r n o t
w o r k in g w it h
a ir s u p .

T r o u b le in
a ir s o u r c e

T r o u b le in
c o n t r o lle r

C heck
C o n t r o lle r

AFR
c o n t a m in a t io n

C le a n
F ilt e r

T r o u b le in
p o s n p ilo t
r e la y

C heck

S t e m / g u id e
g a llin g / ja m m in g

D is a s s e m b le
& check

T r o u b le in
e le c t r ic s o u r c e

C o n tr o l s ig
le a k a g e

C heck
a ir t u b in g

P n tu b in g
Leakage

C h e c k T u b in g
( m a in ly a ir
c o n n .)

A c t d ia p h
a ir le a k

C hange
p a rts

F o r e ig n p a r t ic le
in v lv p o r t

D is a s s e m b le
& check

L e a k a g e fr o m
t u b in g

A c t d ia p h
a ir le a k

C h a n g e p a r ts

T r o u b le w it h
AFR

C heck
A FR

S te m B e n d

C hange
p a rts

C heck com p.
e le c s o u r c e &
M a in a ir t u b in g

P o s it io n e r
a ir le a k

C h a n g e b e llo w
o r d ia p h

T r o u b le in
A c tu a to r

C heck
A c t S tro k e

58

Trouble Shooting in Control Valves.

M A L F U N C T IO N
LEAKAG E

A C T IO N

O TH ERS

C Y C L IC M O T IO N
D r ift o f
a ir s u p p r .
T o o m u c h a ir
c o n s u m p t io n
in o t h e r lin e
E n la r g e
c o m p re s s o r
c a p a c it y

H u n t in g o f
S ig a ir p r .
T r o u b le in
AFR

C heck A FR

C o n t r o l lo o p
R e s is t a n c e

H u n t in g o f
V lv s t e m
T r o u b le in
C o n t r o lle r

In s e rt v o l ta n k
& r e s t r ic t io n t o
a ir s ig n a l lo o p

C heck
C o n t r o lle r

E x c lu s iv e
c o m p re s s o r

59

P o s it io n e r
lo o p h u n t in g

S h ift in p lu g
r e a c t io n fo r c e

C heck posn
p a r t s fr ic t io n

D e c re a s e d P

C heck posn
p ilo t r e la y

H ig h e r s iz e
A c tu a to r

Trouble Shooting in Control Valves.

M A L F U N C T IO N
LEAKAG E

O THER S

S eat Leak

G la n d L e a k

V a lv e C lo s e d

C o r r o s io n & e r o s io n
o f v l v s e a t in g
s u r fa c e

C o r r o s io n & e r o s io n
o f s e a t r in g th r e a d
or gasket

V a lv e n o t
a b le t o c l o s e

Leakage
th r o ' in n e r
v lv b o d y w a ll

T o o h ig h d P

I n s u f f ic i e n t
p k g n u t t ig h t

G a l li n g o n
g u id e o r p o r t

R e m a c h in e & L a p
s e a t s u r fa c e

C hange seat
& seat gasket

T a c k w e ld
d e fe c t a r e a

R educe dP

C h e c k fo r
F o re ig n p a r ts

Change
s e a t & p lu g

C heck
s e a t d e s ig n

C h a n g e v lv
body

In c re a s e
A c t u a t o r s iz e

R e m a c h in e
g a l l i n g p o r t io n

T ig h te n
pkg. nut

P kg Lub
m is s in g

P r o v id e
lu b o r c h g p k g .

W e a r & te a r
of pkg

C hange
pkg

D a m a g e o f s te m
s u rfa c e

C h a n g e p a rts
o r r e m a c h in e

U se dust seal
b e l lo w s

C o r r o s io n / e r o s io n
of seat gasket
s u rfa c e

60

E x a m in e p a r t M O C
C hange gasket

R a n g e a b i li t y n a r r o w e d
because of
c o n t r o l p o s it io n
changed
C o r r o s io n / e r o s io n
o f p l u g o r S . r in g

C h a n g e s e a t r in g
o r p lu g

THANK YOU

61