A 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.
In automatic control terminology, a control valve is termed a "final control element".
Operation
The opening or closing of automatic control valves is usually done by electrical, hydraulic or pneumatic actuators. Normally with a modulating valve, which can be set to any position between fully open and fully closed, valve positioners are used to ensure the valve attains the desired degree of opening.
Air-actuated valves are commonly used because of their simplicity, as they only require a compressed air supply, whereas electrically operated valves require additional cabling and switch gear, and hydraulically actuated valves required high pressure supply and return lines for the hydraulic fluid.
The pneumatic control signals are traditionally based on a pressure range of 3–15 psi (0.2–1.0 bar), or more commonly now, an electrical signal of 4-20mA for industry, or 0–10 V for HVAC systems. Electrical control now often includes a "Smart" communication signal superimposed on the 4–20 mA control current, such that the health and verification of the valve position can be signalled back to the controller. The HART, Fieldbus Foundation, and Profibus are the most common protocols.
An automatic control valve consists of three main parts in which each part exist in several types and designs: Valve actuator – which moves the valve's modulating element, such as ball or butterfly. Valve positioner – which ensures the valve has reached the desired degree of opening. This overcomes the problems of friction and wear. Valve body – in which the modulating element, a plug, globe, ball or butterfly, is contained.
Control action
Taking the example of an air-operated valve, there are two control actions possible:
"Air or current to open" – The flow restriction decreases with increased control signal value. "Air or current to close" – The flow restriction increases with increased control signal value.
There can also be failure to safety modes:
"Air or control signal failure to close" – On failure of compressed air to the actuator, the valve closes under spring pressure or by backup power. "Air or control signal failure to open" – On failure of compressed air to actuator, the valve opens under spring pressure or by backup power.
The modes of failure operation are requirements of the failure to safety process control specification of the plant. In the case of cooling water it may be to fail open, and the case of delivering a chemical it may be to fail closed.
Valve positioners
The fundamental function of a positioner is to deliver pressurized air to the valve actuator, such that the position of the valve stem or shaft corresponds to the set point from the control system. Positioners are typically used when a valve requires throttling action. A positioner requires position feedback from the valve stem or shaft and delivers pneumatic pressure to the actuator to open and close the valve. The positioner must be mounted on or near the control valve assembly. There are three main categories of positioners, depending on the type of control signal, the diagnostic capability, and the communication protocol: pneumatic, analog, and digital.
Pneumatic positioners
Processing units may use pneumatic pressure signaling as the control set point to the control valves. Pressure is typically modulated between 20.7 and 103 kPa (3 to 15 psig) to move the valve from 0 to 100% position. In a common pneumatic positioner, the position of the valve stem or shaft is compared with the position of a bellows that receives the pneumatic control signal. When the input signal increases, the bellows expands and moves a beam. The beam pivots about an input axis, which moves a flapper closer to the nozzle. The nozzle pressure increases, which increases the output pressure to the actuator through a pneumatic amplifier relay. The increased output pressure to the actuator causes the valve stem to move.