DESIGN OF A FLOW CONTROL VALVE
Name: Mohini Kishorsingh Rajput
Batch: G
MIS:111810149
PROBLEM STATEMENT:
Design a Flow control valve for controlling and regulating the flow of water
from corporation storage tank to different water storages of societies through
water pipelines….
Assume suitable water pressure and any other data if required.
Assumptions
1) Water Head =50 m
2) Pipe Diameter = 125 mm
3) Material used for Handle is Steel Carbon.
It's Poisson Ratio 0.27
Introduction:
A flow control valve is a valve used to control fluid flow by varying the size of
the flow passage as directed by a signal from a controller. This enables the
direct control of flow rate and the consequential control of process quantities
such as pressure, temperature, and liquid level. The ability to reduce or
increase pressure in a system has a number of benefits. System operators
can use a flow control valve to rapidly depressurize a serviceable hose and
change fittings quickly. They are also used in many consumer applications
such as showers, faucets, and lawn watering systems to easily reduce the
amount of water consumed without impacting the overall system performance.
Flow control valves are also known for their reliability and typically have a long
operating lifetime as they are not prone to clogging due to their design. Flow
control valves can either be manually operated or automated.
Function of flow control valves:
Flow-control valves, as the name suggests, control the rate of flow of a fluid
through a hydraulic circuit. This can be done either by:
• Stopping and starting fluid flow
• Varying (throttling) the amount of fluid flow
The area of the orifice through which the fluid passes can be varies and thus
flow rate can be controlled. The flow rate is also responsible for determining
the rate of energy transfer at any specific level of pressure, which can be
determined by the flow control valve. By controlling the flow rate, the pressure
and the speed of the fluid can also be controlled.
Types of Flow control valves:
1. Gate valves
Gate valves are general service
valves primarily used for on/off, non-
throttling service. Specifically, gate
valves are used in applications
requiring a straight-line flow of fluid
with minimum restriction is desired.
Gate valves operate when the user
rotates the stem in a clockwise to
close (CTC) motion or a clockwise to open (CTO) motion. The gate moves up
or down on the threaded step when an operator moves the stem, which is why
it is a multi-turn valve; the valve must turn several times for it to go from open
to closed, and it is the slow operation that prevents water hammer effects.
Engineers also utilize gate valves when minimum pressure loss and a free
bore are required. Typical gate valves have no obstruction in the flow path,
which results in a minimal loss of pressure.
Gate valves may be used for several fluids. Generally, gate valves are
applicable for potable water, wastewater, and neutral liquids; in temperatures
between -20 and 70 degrees Celsius; maximum 5 meter/second flow velocity;
and up to 16 bar differential pressure. Gate valves also are applicable for
gases with temperatures between -20 and 60 degrees Celsius; maximum 20
meter/second flow velocity; and up to 16 bar differential [Link] are
two types of gate valves: parallel and wedge-shaped. Parallel gate valves
feature a flat gate between two parallel seats. Wedge-shaped gate valves are
comprised of two inclined seats and an inclined gate that is just a bit
mismatched.
Applications :
1. Suitable for oil, gas, air, heavy liquids, steam, non-condensing gases,
abrasive and corrosive liquids
2. Gate valves without an extra sealing ring on the gate or the seat are
used in applications where minor leaking of the valve is not an issue,
such as heating circuits or sewer pipes.
• Best Suited Control: Quick Opening
• Recommended Uses: 1. Fully open/closed, non-throttling
Advantages: • High capacity • Tight shutoff • Low cost • Little resistance to
flow • Ability to cut through slurries, scale and surface build-ups • Provide
unobstructed flow paths that not only provide high flow capacity (Cv), but even
allows slurry, large objects, rocks and items routinely found in mining
processes to safely pass through the valve.
Disadvantages: • Poor control • Cavitate at low pressure drops • Cannot be
used for throttling • Relatively low pressure limitation - general pressure
limitations are 150 psi at maximum.
2. Globe valves:
A linear motion valve, globe valves stop, start,
and regulate flow. Globe valves initiate closure
via a plug featuring a flat or convex bottom that
is lowered onto a horizontal seat situated in the
centre of the valve. When a user opens the
valve, the plug raises to allow fluid to flow.
Globe valves are used for on/off and throttling
applications because the disk of the valve can
be removed from the flow path completely or it
can completely close the flow path. While this
type of flow control valve does produce slightly higher pressure drops than
straight-through valves like gate, plug, and ball valves, they are applicable in
situations where the pressure drop through the valve is not a controlling factor.
Applications:
1. Suitable for most liquids, vapours, gases, corrosive substances
2. To control large range of process parameters, specially for oil and gas
production, power generation, chemical, petrochemical, fertilizer,
pharmaceutical, processed food and other process industries
• Best Suited Control: Linear and Equal percentage
• Recommended Uses:
Applications requiring: 1. Precise flow regulation
2. Frequent and wide throttling operation
3. Suited to very high pressure drops
Advantages: • Efficient and precise throttling • Accurate flow control
Disadvantages: • Low recovery and relatively low coefficient of flow (Cv). •
High pressure drop, higher pump capacity and system wear • More expensive
than other valves • The sealing device is a plug that offers limited shut-off
capabilities, not always meeting bubble tight requirements.
3. Ball valve:
Ball valves are commonly used in flow systems across
numerous industries due to their low cost, durability, and
excellent shutoff capability. Similar to butterfly valves, they
are not as effective for flow control applications that require
a high degree of accuracy and control. One of the reasons
for this is that a ball valve requires a high degree of torque
to open and close that prevents an operator from making
fine adjustments. There is also a certain amount of “play”
between the stem and the ball which can make finding specific flow rates
difficult. For flow control applications where a ball valve is possible, such as
filling a tank to a reasonable degree of accuracy, a trunnion or v-port ball valve
design is usually the best choice. Ball valves are a quick opening valves that
give a tight shutoff. When fully open, a ball valve creates little turbulence or
resistance to flow. The valve stem rotates a ball which contains an opening.
The ball opening can be positioned in the fully open or fully closed position but
must not be used to throttle flow as any abrasive wear to the ball will cause
leakage when the valve is closed.
Application:
[Link] valves are excellent in chemical applications, including the most
challenging services (e.g. dry chlorine, hydrofluoric acid, oxygen).
• Best Suitd Control: Quick opening, linear
• Recommended Uses:
• Fully open/closed, limited-throttling
• Higher temperature fluids
Advantages: • Low cost • High flow capacity • High pressure/temperature
capabilities • Low leakage and maintenance • Tight sealing with low torque •
Easy quarter turn operation- desirable to most operators • Fairly easy to
automate.
Disadvantages: • Limited throttling characteristics • Prone to cavitation • Not
suitable for slurry applications due to cavities around the ball and seats.
Slurries tend to solidify or clog inside the cavities, greatly increasing the
operating torque of the valve and in some cases rendering the valve
inoperable
[Link] valve:
A butterfly valve is operated by rotating a
disk within the flow area and, due to this
design, it doesnot have linear flow
characteristics. This makes these valves
less precise than the more common flow
control valve types above. For this reason,
it can often be dismissed as a flow control
valve choice even though it is useful in
some applications that do not require a very high degree of accuracy. They
are also a very affordable valve option, which makes it worthwhile to consider
them in the right applications.
Applications:
1. Most economical for large lines in chemical services, water treatment,
and fire protection systems.
Best Suited Control: Linear, Equal percentage
Recommended Uses:
• Fully open/closed or throttling services
• Frequent operation
• Minimal fluid trapping in line
• Minimal fluid trapping in line
Advantages: • Low cost and maintenance • High capacity • Good flow control •
Low pressure drop
Disadvantages: • High torque required for control • Prone to cavitation at lower
flows • Lack of cleanliness and inability to handle slurry applications. •
Generally not rated as bubble tight, and the cavities and leak paths around the
disc stem are potential entrapments for fluids and slurries. Some high
performance butterfly valves meeting ASME class VI leakage ratings are
however available on demand.
5. Pinch valves
A cost-effective flow control
valve, pinch valves are ideal for
applications of slurries or liquids
containing significant amounts of
suspended solids. Pinch valves seal
using one or more flexible elements like rubber tubes that
become pinched to turn off the flow. These rubber sleeves are the valve’s only
wetted part, and their flexibility allows pinch valves to close tightly around
entrapped solids. Air or hydraulic pressure is placed directly on the elastomer
sleeve to actuate pinch valves. A pinch valve’s body acts as a built-in actuator,
which eliminates expensive hydraulic, pneumatic, or electric operators and
results in the cost-effectiveness of this type of flow control valve.
Application:
• Bulk and solids handling,
• Cement industry,
• Waste water industry,
• Chemical industry,
• Food industry,
• Beverage industry,
• Ceramic-/Glass-/Plastic industry.
Advantages :
• It can be used for application where corrosion or metal
contamination of the fluid might be a problem. Flow from the
valve is straight without any obstruction.
• There are no internal moving parts in contact with the fluid hence,
low maintenance cost.
• Inexpensive due to simple construction
Disadvantges:
• It cannot be used in high temperature-pressure applications and
gas media.
6. Diaphragm valves
Diaphragm valves are characterized by a flexible disc
that contacts a seat at the top of the valve body and
forms a seal. The diaphragm is flexible and pressure-
responsive; it transmits force to open, close, or control
a valve. While diaphragm valves are related to pinch
valves, they use an elastomeric diaphragm rather than
an elastomeric liner in the valve body. The elastomeric
diaphragm is attached to a compressor and separates
the flow stream from the closure element. Diaphragm valves are ideal for
handling corrosive, erosive, and dirty services.
There are many advantages to using diaphragm valves: they are extremely
clean, feature a leak-proof seal, have a tight shut-off, are easy to maintain,
and reduce leakage to the environment. Diaphragm valves also may be
repaired without interrupting a pipeline. On the other hand, the disadvantages
of using diaphragm valves include only being able to use them in moderate
temperatures of -60 to 450 degrees Fahrenheit and in moderate pressures of
approximately 300psi. Diaphragm valves cannot be used in multi-turn
operations and do not have industry standard face-to-face dimensions. Also,
the body of a diaphragm valve must be made of corrosive-resistant materials.
Applications :
[Link] water treatment plant, caustic soda plant, chemical plants, fertilizers,
specially for corrosive fluid.
2. Clean or dirty water and air service applications.
[Link]-mineralized water systems.
[Link] applications.
[Link] systems in nuclear facilities.
[Link] service.
[Link] processing, pharmaceutical, and brewing systems.
8. Diaphragm valves are particularly suited for the handling of corrosive fluids,
fibrous slurries, radioactive fluids, or other fluids that must remain free from
contamination
Advantages of Diaphragm Valves
▪ Diaphragm valves can also be used for throttling service.
▪ Its throttling characteristics are essentially those of a quick opening
valve because of the large shutoff area along the seat.
▪ The operating mechanism of a diaphragm valve is not exposed to
the media within the pipeline. Sticky or viscous fluids cannot get
into the bonnet to interfere with the operating mechanism.
▪ Many fluids that would clog , corrode, or gum up the working parts
of most other types of valves will pass through a diaphragm valve
without causing problems. Conversely, lubricants used for the
operating mechanism cannot be allowed to contaminate the fluid
being handled.
▪ There are no packing glands to maintain and no possibility of stem
leakage in valves.
Disadvantages of Diaphragm Valves
▪ Valve transition has sets, preventing the pipeline from complete
discharge.
▪ The operation temperature and pressure have limits depending on
the diaphragm material. Typically, they are used under 200 psi
(14bar) pressure and 204ºC temperature limits.
▪ The hydrostatic pressure that can be applied to the diaphragm is
limited.
▪ Dimensions of diaphragm valves are limited. They are produced in
DN15-DN300 dimensions.
7. Needle Valves:
Needle valves are volume control valves that restrict
flow in small lines. Fluid moving through the valve
turns 90 degrees and flows through an orifice that
serves as the seat for a cone-shape-tipped rod. The
orifice size changes when the user positions the cone
in relation to the seat. Needle valves are similar to
globe valves in that they share a few design features
and have similar benefits; for example, both needle
valves and globe valves empower operators to change flow rate using a
threaded rotating stem. The difference between needle valves and globe
valves is the precision that needle valves can achieve. In fact, needle valves
are an ideal choice for calibration applications because they are capable of
being fine-tuned.
Needle valves can provide positive shutoff in order to
allow gauges and other measurement instruments to
be installed or removed safely. That’s also why
needle valves may be used in a range of industries,
from petrochemicals to biofuels. It is the needle
valve’s finely-threaded valve stem that gives it a
significant mechanical advantage by allowing operators to seal it using only
minimal force. One disadvantage of needle valves, however, is that the visual
inspection alone is not enough to determine whether a needle valve is open or
closed.
Applications:
1. In water treatment and distribution, dams, reservoirs, power plants and
industry needle valves are used.
2. The needle valves can be used with higher differential pressure.
3. Automatic combustion control systems
4. Most constant pressure pump governors have needle valves to
minimize the effects of fluctuations in pump discharge pressure.
Advantages of Needle valve
The main advantages that a needle valve serves are
1. With the help of this valve flow control at a very low rate with higher
accuracy is possible.
2. Needle valves are smaller in size. So, there is not an issue of space
during its installation.
3. Throttling even with less volume of fluid is possible with this valve.
4. Flow rates can be adjusted precisely.
5. Its operation is easier.
Disadvantages of Needle valve
Few drawbacks of needle valves are
1. There is a high-pressure loss in the needle valve because of the high
restriction of fluid flow.
2. They can be used only for low flow rate piping systems.
3. There can be damage to the seat and needle if the fluid has solid
particles.
4. It is not possible to say if it is in an open or close position just by
examining the handle position.
5. Immediate opening or closing is not possible in these types of valves.
Immediate operations can damage the seat of the need valve.
[Link] valve:
Plug valves come in a variety of configurations and are
operated by rotating a cylindrical or cone-shaped plug
within the valve body to regulate the flow through a
hollow area of the plug. For flow control applications
the most common design is an eccentric plug valve,
which uses a half plug to create a higher seating force
with minimal friction as it is opened and closed. This
has the advantage of greater shut off capability which is ideal for flow control
situations.
Applications:
1. They are primarily used in bubble-tight services as on-off stop valves.
The wiping-off action of a plug does not permit suspended particles to
accumulate and form crud.
2. Air, gaseous, and vapor services. Coal slurries, mineral ores, mud, and
sewage applications
Advantages of Plug Valves
The following summarizes the advantages of plug valves:
1. Simple design with few parts.
2. Quick to open or close.
3. Can be serviced in place.
4. Offers minimal resistance to flow.
5. Provides reliable leaktight service. Seal can be maintained by injection of
sealant or by replacement of sleeve, in addition to utilizing the wedging action
of a tapered plug.
6. Multiple port design helps reduce number of valves needed and permits
change in flow direction.
Disadvantages of Plug Valves
The disadvantages include:
1. Requires greater force to actuate, due to high friction.
2. NPS 4 (DN 100) and larger valves require use of actuators.
3. Reduced port, due to tapered plug.
4. Typically, plug valves may cost more than ball valves
Why Butterfly Valve as flow control valve ?
The butterfly valve was originally used where a tight closure was not
absolutely necessary. However, over the years, these valves have been
manufactured with fairly tight seals made of rubber or elastomeric materials
that provide good shut off similar to other types of valves. Butterfly valves are
used where space is limited. Unlike gate valves, butterfly valves can be used
for throttling or regulating flow as well as in the full open and fully closed
position. The pressure loss through a butterfly valve is small in comparison
with the gate [Link] valves tend to be cheaper than gate valves
because they require less material and less civil works. They are also easier
to operate against unbalanced water pressures as the disc pivots about an
axis on or near the pipe axis.
Butterfly Valve
(1)Design of Disc:
(i)Material Selection:
There is low pressure at disc section when it is opened,so stainless steel has
excellent machinability and corrosion resistance and are used for relatively
small valves in low-pressure [Link] steel has superior corrosion
resistance, heat resistance, low-temperature resistance and excellent
mechanicalproperties.
(ii) Function:
Used to control the water flow in flow control [Link] variable angle of disc
regulates the pressure difference across the valve.
(iii)Possible modes of failure:
a) Bending moment due to force of water flow(pressure head)
b) Shear Stress by Pressure head.
(iv)Critical mode of failure:
Bending moment due to Pressure head of water
(v)Design:
(2)Design of Stem
(i) Material Selection:
Stainless Steel is tougher, more durable metal than cast iron, ductile
iron, brass or copper. Stainless steel materials get their designation from
thefact that they are very corrosion resistant. Their toughness and strength
make stainless steels a useful material option for compact miniature used in
stem of flow control valves.
(ii) Function:
The function of stem is to rotate the disc as and when required to change the
pressure of water at the output
(iii) Possible modes of failure:
a) Torsion deformation failure.
b)Steam fracture or steam misalignment along the disc and ring.
c)Bending stress due to Pressure head
(iv)Critical mode of failure:
a) Bending Moment due to Pressure head
b)Torsional shear stress
(v)Design:
(3)Design of Ring
(i)Material Selection:
We use carbon steel (Syt=230N/mm^2) for ring so that it can handle pressure
head of water.
(ii)Possible modes of failure:
a) Bending moment due to water flow
b)Corrosion and wear.
(iii)Critical mode of failure:
Bending stress by Pressure of water
(iv)Design:
We use 3 F. O. S bcoz we use flow control butterfly valve for 50 m head. So
the pressure is higher. So to avoid failure and due to high pressure rusting
takes place so to avoid it we use this f. O. Ss
(3)Design of Handle
(i)Material Selection:
We use Steel 30C8 (Syt=400) for handle because it is subjected to bending
moment and yield strength is criterion for selection of material.
(ii)Possible modes of failure:
a) Bending moment due to torque exerted by hand operation
b)Torque shear stress due to stem
(iii)Critical mode of failure:
Bending moment by manual hand operation
(iv)Design:
AssemblyDrawing
Part Drawing:
CREATED BY
MOHINI RAJPUT
M