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Contents
Control Valve ............................................................................................................... 2
Introduction:............................................................................................................. 2
Purpose of Control Valve: .......................................................................................... 2
Classification of Control Valves: ................................................................................. 2
Construction: ............................................................................................................ 6
Working of a Control Valve System: ......................................................................... 10
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Control Valve:
Introduction:
A control valve is a power-operated device used to regulate the flow of fluids (like gas, oil, water,
or steam) by varying the size of the flow passage, typically in response to a signal from a
controller.

It's a crucial component in many industrial processes, acting as a "final control element" within a
control loop. Control valves are used to maintain process variables like pressure, temperature, or
flow rate at desired set points.

Control valves is a broader terminology that includes throttling valves (control valves) but also
valves like shut down valves that works on different working principle but still plays a prominent
role in process control and plant safety.

Purpose of Control Valve:

The primary purpose of a control valve is to regulate the flow of a fluid within a process system.
This regulation helps maintain the desired process conditions such as flow rate, pressure,
temperature, or liquid level.

Main Purposes:
Although the control valve can be used in a wide range of ways but the most applications of a
controller are.
1. Flow Control
To increase or decrease the flow rate of a fluid as required by the process.
2. Pressure Control
To maintain system pressure within safe and desired limits by throttling the flow.
3. Temperature Control
By controlling the flow of heating or cooling fluids, it helps regulate temperature.
4. Level Control
Used in tanks and vessels to maintain the liquid level by adjusting inflow or outflow.

Classification of Control Valves:

Different types of valves are used in a variety of industries and applications to shut off, regulate
and control the flow, pressure, and direction of fluids and gases, such as gate valves, globe valves,
ball valves, check valves, butterfly valves, and other valves.

Control valves can be classified based on several criteria, primarily focusing on their motion
(linear or rotary), the type of actuator used (electric, pneumatic, or hydraulic), and their specific
application.
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Based on Action:
Control valves can be classified into four types based on the direction of their actuator and valve
action.

1. Direct Acting – Direct Actuator:

• When air pressure increases, the actuator pushes the stem down, the valve closes.
• Fail-safe condition: If air fails, spring pushes the stem up → Valve opens (Fail Open).

Air supplied from top of Valve stem moves

valve closes
Actuator down

2. Direct Acting – Reverse Actuator

• How it works: When air pressure increases, the actuator pulls the stem up; the valve
opens.
• Fail-safe condition: If air fails, spring pushes stem down → Valve closes (Fail Close).

Air supplied from

Valve stem moves up valve opens
bottom of Actuator

3. Reverse Acting – Direct Actuator

• How it works: When air pressure increases, the actuator pushes the stem down; the
valve opens.
• Fail-safe condition: If air fails, spring pushes the stem up → Valve closes (Fail Close).

Air supplied from top of Valve stem moves

valve opens
Actuator down

4. Reverse Acting – Reverse Actuator

• How it works: When air pressure increases, the actuator pulls the stem up; the valve
closes.
• Fail-safe condition: If air fails, spring pushes stem down → Valve opens (Fail Open).

Air supplied from

Valve stem moves up valve closes
bottom of Actuator
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Based on Valve Body Type:

Control valves are also classified based on their body design and flow control
mechanism. Here are the common types:

1. Globe Valve

• Working: Has a plug (disc) that moves up/down against the flow inside a
globe-shaped body.

• Use: Precise flow control (good throttling).

• Advantage: Accurate; tight shut-off.

• Limitation: Higher pressure drop.

2. Butterfly Valve
• Working: A disc rotates within the flow path (like a wing flap) to control flow.
• Use: On/off and some throttling.

• Advantage: Compact, lightweight.

• Limitation: Not ideal for precise control.

3. Ball Valve

• Working: A ball with a hole rotates to allow or block flow.

• Use: Fast on/off service.
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• Advantage: Low pressure drop, quick operation.

• Limitation: Not suitable for throttling.

4. Diaphragm Valve

• Working: A flexible diaphragm presses down to close the flow path.

• Use: Corrosive or slurry fluids.

• Advantage: Leak-proof, clean operation.

• Limitation: Not for high-pressure systems.

5. Plug Valve

• Working: A tapered or cylindrical plug rotates inside the valve body.

• Use: On/off service.

• Advantage: Simple design, quick operation.

• Limitation: Limited throttling may require more torque

Based on Flow Control Characteristics:

This classification is based on how the flow rate changes with respect to valve opening
position.

1. Linear

• Flow change: Flow increases equally with equal movement

of the valve (e.g., 10% opening = 10% flow).
• Use:
o When load changes are steady and predictable for
example tank level control, Steam and water systems
with steady conditions etc.
• Advantage: Easy to control at mid-range.
2. Equal Percentage

• Flow change: Each increase in valve position causes a

percentage increase in flow (slow at first, faster later).

• Use:

o Ideal for varying pressure drops and wide flow range for example Heat exchangers,
HVAC systems, Gas and vapor control.
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• Advantage: Good control at low openings.

3. Quick Opening

• Flow change: Large increase in flow with small valve movement at the beginning.
• Use: On/off service or safety applications.
• Advantage: Fast flow at low openings, for example safety relief bypasses, ESDVs etc.

The flow characteristics of a control valve are mainly determined by the shape of the valve plug
and how it moves relative to the seat. While the seat itself provides the sealing surface, it is the
profile of the plug that controls how much flow area is opened as the plug moves. A linear plug
has a shape that increases flow area evenly with stem movement, an equal percentage plug
gradually increases flow area at first and then more rapidly, and a quick opening plug provides a
large flow area with minimal movement. The seat remains generally the same, but it works in
coordination with the plug to define the overall flow vs. position behavior of the valve.

Construction:
Major Components of a Control Valve:
Regardless of type, all valves have the same basic components as body, bonnet, trim (internal
elements), actuator, and packing, they differ in parts like positioner and SOV (Solenoid operated
valve).

Control Valves mainly have Two parts:

1) Actuator Part

2) Body Part
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Actuator Part:
Rain Cap
An actuator is a device that moves or controls a valve based
on a signal from a controller. It converts energy (air
Diaphragm
pressure, electric current, or hydraulic fluid) into
mechanical motion to open, close, or modulate the valve
bench set
position.

For valve control, actuators are generally classified as Actuator Part Actuator Stem
pneumatic, motorized (electric), or hydraulic, based on their
source of power. In most process industries, the pneumatic Scale Plate
actuator is the most used due to its fast response, simplicity,
and reliability. Stem Connector

Valve Components
Pneumatic actuators operate using compressed air to move
Yoke
the valve stem, making them suitable for applications
requiring quick and repetitive movements.
Gland Packing
In contrast, motorized actuators use electric motors to
control valve position and are often used where air supply Valve Stem
is not available. Hydraulic actuators, powered by
pressurized oil or fluid, provide very high force and are Bonnet
typically used in heavy-duty applications where stronger
torque is needed, such as in large valves or high-pressure Body Part Gasket
systems. Each actuator type is selected based on the
application requirement, control precision, and available Valve Plug
utilities.
Seat Ring
Various components of the Actuator body are
Valve Body
• Rain Cap
The rain cap protects the actuator from rain, dust,
and debris. It prevents moisture and contaminants from entering, ensuring reliable
operation and a longer service life, especially in outdoor or harsh environments.
• Diaphragm
A flexible membrane that responds to air pressure. It transfers the force from compressed
air to the diaphragm plate, which moves the actuator stem to control valve movement.
• Bench Set
The bench set refers to the initial spring compression in the actuator before installation. It
defines the air pressure range required to fully open or close the valve (e.g., 6–18 psi).
• Actuator Stem
This is the moving shaft inside the actuator that connects to the valve stem. It transfers
motion from the diaphragm or piston to the valve.
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• Stem Connector
This component links the actuator stem to the valve plug stem. It ensures smooth
transmission of force between the actuator and the valve.
• Scale Plate
A position indicator that shows the valve opening from 0% (fully closed) to 100% (fully
open). It helps in monitoring and adjusting valve position.
• Yoke
The yoke is the structural part that connects the actuator to the valve body. It provides
mechanical support and serves as a mounting point for accessories like positioners or
handwheels.

Body Part
Various components of the body are

Gland Packing
Gland packing is used to prevent fluid leakage along the valve stem where it exits the bonnet. It
is in direct contact with the valve stem and bonnet.

Valve Stem
The valve stem connects the actuator or handwheel to the valve plug. It transmits force to move
the plug for controlling flow. It must be strong and precisely aligned to ensure smooth valve
operation.
Bonnet
The bonnet is the upper portion of the valve body that houses the stem, packing, and supports the
plug. It helps maintain alignment between the plug and seat. Some manufacturers may reduce
bonnet design for cost efficiency, but this can make maintenance difficult and affect valve
performance.

Gasket
A gasket is placed between the valve body and bonnet to prevent leakage at the joint. It is
commonly made of materials suitable for sealing between metal surfaces, such as iron and steel.

Valve Plug
The valve plug is the moving part inside the valve that regulates fluid flow. It determines the
valve’s flow characteristic—linear, equal percentage, or quick opening—depending on its shape
and design.

Seat Ring
The seat ring is a fixed component inside the valve body that forms a sealing surface for the
plug. It also influences valve flow capacity. The plug and seat ring must fit closely to meet the
required leakage class.
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Other components that are not common, but an essential part of the control valve used for
throttling are

1. Positioner:

A positioner is a device mounted on a control valve that ensures the valve stem reaches the
exact position according to the control signal it receives. It compares the input signal from the
controller with the actual stem position and adjusts air pressure to the actuator to match the
desired position.

Types of Positioners

o Pneumatic Positioner
o The mode of input signal in the positioner is Pneumatic (usually 3–15 psi)
o Uses air pressure for both signal and control
o Common in older or air-only systems
2. Electro-Pneumatic (I/P) Positioner
o The mode of input signal in (I/P) positioner is Electrical (usually 4–20 mA)
o Converts electrical signal to pneumatic output
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o Widely used in modern process plants

3. Digital or Smart Positioner
o The mode of input signal in digital positioner are Digital (HART, Foundation
Fieldbus, etc.)
o Microprocessor-based, allows advanced diagnostics, remote calibration, and
communication
o High accuracy and smart control features

2. I/P Converter (Current to Pressure Converter):An I/P converter is a device that converts
an electrical signal (usually 4–20 mA) into a proportional pneumatic output pressure
(usually 3–15 psi). It is commonly used in electro-pneumatic control systems, especially
to interface electronic controllers with pneumatic actuators or positioners.

3. Solenoid Operated Valve (SOV)

A solenoid operated valve, or SOV, is an electrically controlled valve that uses a solenoid
(electromagnetic coil) to open or close the valve. It is widely used for on/off control of fluid or
gas flow in automation and safety systems.

Used with Shut down valves or valves where on/off control is required. Usually not used for
throttling purposes.

4. Pressure Regulator:

A pressure regulator is a device used to automatically maintain constant downstream pressure,

regardless of fluctuations in inlet pressure or flow demand. It is essential in systems where
pressure control is critical for safety, efficiency, and equipment protection.

It is placed at the upstream of both I/P and positioners providing a steady pressure of 20 psi to
I/P and around 40 psi to positioner (dependent of bench set requirement).

5. Quick exhaust:

A quick exhaust valve is a device used in pneumatic systems to rapidly vent air from the
actuator, allowing for faster retraction or movement. Instead of routing exhaust air back
through the control valve, the quick exhaust valve provides a direct exit path for the air. This
significantly improves response time and is especially useful in applications where fast
actuation is required, such as in double-acting cylinders, pneumatic actuators, or emergency
shutdown systems.

Working of a Control Valve System:

1. Signal from CCR (Central Control Room):
• The control system (DCS/PLC) in the CCR sends an electrical signal (typically 4–20 mA)
to the I/P converter.
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• This signal represents the required valve opening based on process conditions (flow,
pressure, level, etc.).

2. I/P Converter Action:

• The I/P (Current to Pressure) converter converts the 4–20 mA electrical signal into a
proportional pneumatic signal (usually 3–15 psi).

• This pneumatic signal is then sent to the positioner.

3. Pressure Regulator Role:

• A pressure regulator installed upstream ensures a constant and safe air supply pressure
(e.g., 20–30 psi) to the I/P and positioner.

• It protects components from pressure fluctuations or overpressure.

4. Positioner Operation:

• The positioner receives the pneumatic signal from the I/P and compares it to the actual
position of the valve stem using mechanical feedback.

• If there is a mismatch, the positioner adjusts air flow to the actuator until the stem reaches
the correct position.

• This ensures precise valve opening corresponding to the CCR signal.

• Valve opens proportionally:

o 3 psig = 0% open

o 6 psig = 25% open

o 9 psig = 50% open

o 12 psig = 75% open

o 15 psig = 100% open

5. Actuator Response:

• The pneumatic actuator (diaphragm or piston type) receives the air from the positioner and
moves the actuator stem.

• The actuator stem moves the valve plug, which controls the flow of fluid through the valve.
6. Quick Exhaust Valve Action:

• When the signal to close (or open) the valve is suddenly removed or reduced, the quick
exhaust valve vents the air in the actuator chamber directly to the atmosphere.
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• This provides faster valve movement, useful in emergency shutoff or fast-acting

applications.