How a Control Valve Works? > A control valve is an necessary equipment in industrial and manufacturing units. But what is a control valve, exactly? And what control valve does it do?
Simply, a control valve is a equipment that regulates the fluid flow (gas or liquid) through a system or pipe. Control valve controlling the percentage of opening in the valve, which can be opened narrower or wider as required to get the required flow rate.
How a Control Valve Works? Control Valve Types and Applications
There are many various kinds of control valves, each with its own special set of applications. But they all use common goal: to help regulate and control the fluids flow through a system or pipe.
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What Are the Different Types of Control Valves?
There are a few different kinds of control valves that are generally used in many industries. Most popular kinds are the ball valve, plug valve, diaphragm valve, globe valve and butterfly valve, angle valve. All types of control valves work differently but all use in the same purpose of controlling pressure and flow rate and to the system.
Every kind of control valve has its own unique set of drawbacks and benefits.
- Globe valves are best for controlling the liquid flow, while ball valves are better for controlling the gasses flow. Globe valve typically use in process control applications as they give precise control and tight shutoff.
- Butterfly valves, on the other hand, are versatile sufficient to be used for both gases and liquids. They’re also simple to operate and can be closed and opened quickly. Butterfly valves gives a high accurate flow control option for high-volume applications with low-pressure drops.
- Angle valves are great for high flow rate requirement and low pressure drops.
- Ball valves are much better than other kind of control valve to control temperatures up to 250 degrees Fahrenheit and can be simply automated with actuators.
- Plug valve use for regulating the flow in pipelines with minimal pressure loss but cannot be good for very high temperature applications.
- Diaphragm valves makes them simple for using and maintaining, simple design making them ideal to regulate delicate materials or steam applications.
How a Control Valve Works?
For the water distribution system, control valve is a critical part. For regulate the water pressure and flow at a consistent rate, control valve responsible.
Without a control valve, pressure of water would be all over the place. It would be too more when the faucet was turned on and too low when it turned off. It would generate an inconsistent flow and make it difficult to get the water to reach all of the faucets in your home.
The control valve solves this kind of problem by regulating the fluid pressure and maintaining a consistent fluid flow.
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The Benefits and Drawbacks of Control Valves
Control valves have a range of advantages and drawbacks that you should be aware of before purchasing.
On the other side, control valves offer precise controlling the flow and can save you money on energy price. They’re also reliable, durable, and can handle a wide range of fluid temperatures and pressures.
However, control valves also have some expensive to purchase and maintain, and they need to regulate the calibration and cleaning to ensure optimal performance.
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Troubleshooting Common Issues With Control Valves
In case of troubleshooting of control valves, there are a some common problems that you may run into. The first is air availability in the system, which is created by a leak in the valve or by not bleeding properly the system before it starting.
The second issue is leakage, which is typically created by a worn-out seal or dirt on the seal itself. It can lead to excess pressure drop and will need to replace the valve.
Another issue is a stuck valve stem, means the valve won’t open or close properly. If this issue happens due to corrosion or dirt build-up within the body of valve. This issue can be fix with some cleaning and lubrication, but if not then require to replace the valve.
Finally, regularly check any insulation surrounding the control valves to make sure it isn’t worn out or cracked. A worn out or cracked insulation layer can create heat transfer and can be responsible for control valve damage problem.
Tips for Trouble-Free Operation of a Control Valve
Generally, control valves are designed for trouble-free operation, there are few facts you should be aware for better performance and longevity of control valve.
First, when control valve installed, it should be in line with the flow direction of the system. If control valve installed against flow direction , then it can lead to uneven fluid pressure and decrease efficiency.
Second, should be check any impurities or sediment in availability in the system that could be responsible for damage to the internals of the valve and rob performance. If impurities and sediments seem in the line, then it’s a nice idea to flush out the system before you operate the valve.
In case of manual control valve, be sure not to exceed its turn limit, because of it can damage both its internal components and seals. If you use an automated control valve, then it should be properly calibrated for working correctly.
These are just few tips related to control valves to stay healthy and perform optimally.
Components of a Control Valve
Although control valves design look quite very simple, they are actually have several components. Many of them are the same regardless of the kind of control valve, and they have valve body, actuator, actuator stem, valve plug and seat ring.
The main part of the valve is valve body and it houses all the other components. The actuator is linked to a stem. Stem linked to the plug and plug sits in the seat ring. Applied pressure on plug will move and open or close the valve.
The actuator permits for precise control and regulate the pressure as well as flow rate, making it perfect to use in different kind of processes like as controlling water pressure for irrigation or giving reliable air flow in air conditioning units.
Many modern control valves have sensing devices like as temperature sensors or pressure switches aids to further regulate the flow rates and other kind of parameters even more accurately.
How Do You Repair a Control Valve?
It needs to know about important question “How do you repair a control vale?”
The process get started with the removing of the obsolete or broken valve. Once the valve got removed, starts cleaning the for new for the new valve. Then, check the pipe sizes and connection types for matching up before installing the new valve.
Depending on the kind of control valve, adjustments may be takes place during installation. For instance, a pressure reducing valve might required specific pressures for setting in order for regulating the pressure properly. Once everything is placed properly and has been tested, control valve be ready for processing.
Control Valve Accessories
In this article ” How a Control Valve Works? “, there are some of the accessories commonly used with control valves. These accessories are important for helping to keep the control valve functioning properly, and can help to improve the life of the valve.
The most common accessory of control valve is the actuation package. The actuation package mechanism used to move the control valve into its required position, usually using either electric or pneumatic power. The electric actuation package typically used with electrical motor to move the control valve, and is mostly used for big control valves. The pneumatic actuation package used for compressing the air or gas to move the valve, and is more common for small kind of valves.
Another most common accessory is a positioned, which helps to open and close control valve to the desired parameters. This helps improve the accuracy during the controlling flow rate or pressure. Lastly, it is better to install filters and strainers before any control valve for keeping foreign material out of it and avoid any damage. It’s also necessary that filters should be regularly maintained and cleaned so they work properly.
In this article ” How a Control Valve Works? “, all in all, the control valve known as a critical part of any plumbing system. It aids to maintain water pressure and keeps taps and faucets flowing smoothly. During the low water pressure, or if taps and faucets are leaking, it requires to inspect and repair the control valve.
Control valves have few applications according to type of industries and applications, like- oil and gas production, manufacturing, process & engineering. They used for controlling the flow of fluids. like- air, water, steam & gasoline.