Automatic control valves, much like everything else we purchase these days, are not all created equal. Some fall into the high quality bracket with pricing to match, while others hover closer to the lower quality and price sensitive end of the scale. Unfortunately, when evaluating control valve prices, it is not always clear what you are being offered and what standards the valve actually meets. Here are a few questions to consider and ask the supplier to ensure you get years of trouble free operation that lasts longer than it takes the sales person to drive out of your parking lot!
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Q 1 What materials are being used?
Make sure you know what the different components of the valve are made of, as this will certainly affect the life of your valve, specifically:
Body Material &#; is the valve body cast iron or ductile iron? Traditionally valves were cast iron but ductile iron has become the new standard due to its superior physical properties that are much better at weathering the elements.
Body Coating &#; Most of the world insists on fusion bonded coating of a valve, inside and out. Unfortunately here in North America, that is not always requested. This just makes common sense for valves that are constantly wet and sit in locations that are not always dry and pristine. A valve should last for many years, so insisting on a coated valve is a wise choice.
Seat Material &#; bronze is typically the common material for seats but over time, depending on water quality and velocities, bronze wears resulting in the need for replacement. This is time consuming and expensive as seat replacement requires a complete disassembly of the entire valve. Ideally go for stainless steel.
Valve Internals &#; Most valve manufacturers utilize stainless steel for their valve stems. Make sure that you ask what grade of stainless you are getting as not all stainless steel is created equal. 316 SS is always the best choice because it is harder and least likely to corrode.
External Fasteners &#; Over time valves experience condensation or flooding and this can play havoc with coated studs or bolts. There is nothing worse than trying to remove heavily rusted studs out of an old valve to perform maintenance. Request stainless steel fasteners as this will ensure that bolts will be removable at any age.
Q 2 Does the valve supplier fully understand your application?
Too frequently a specification will be requested and a valve is supplied that is simply the wrong valve for the job. It may also be the case that there is just a better solution. Ensure you give your valve supplier all the necessary pressure and flow details including details of the actual application and what you want this valve to do. Having the wrong valve for the wrong application, at best case will result in a significantly shorter life and worst case, a malfunction that can result in destruction of the valve and other parts of your water distribution system.
Q 3 Will this new valve fit into my existing piping layout?
Don&#;t be tempted to just stay with brand X because that is the valve you may be replacing and has the same lay lengths. Most manufactures can be quite innovative on providing solutions to combat varying lay lengths so explore all of you options rather than just settling because you think it may be easier.
Q 4 Do you need specialty tools for maintenance?
Nobody wants to have to carry around a specific tool that only performs one task. Ensure that your valve can be maintained with everything you would carry in regular tool kit. Some valve manufacturers require specialized seat removal tools, or vice jaws installed with copper jaws to protect valve stems. While these are great ideas, they are certainly not things that the average operator has in his toolkit.
Q 5 Will your personnel receive complimentary factory qualified training?
Control valves are not so difficult to understand and once taught, most operations personnel can easily perform maintenance. Ensure that you will not be reliant on the additional cost of having to bring out a factory person every time your valve requires maintenance. Request that a factory-trained representative is on site when the valve is commissioned. This will allow your operators to be schooled in the regular maintenance needs, know what to look for if things go awry and how to start up a valve in a new system or after service. Simple tricks like removing air out of the pilot system are valuable lessons to see in practice.
Q 6 Does your valve have a solid warranty?
These days having a product with the long term back up of the factory is important. Three years should be the standard to ensure there are no manufacturing faults.
Q 7 Can I make changes to the valve if required
Having a valve &#;expansion ready&#; for the future can save you money and make your decisions a whole lot easier. For example, can you add a limit switch or a position indicator easily? Or, if you need to move the pilot system to the other side of the valve, can you do it, or is it not possible because the valve body does not have the required connections? Things always change and a flexible valve gives you more options to keep your now perfect valve, perfect down the road.
Q 8 Does your valve meet industry standards?
There are third party accreditations that ensure your valve was built to the correct specifications. For example; NSF 61, WRAS, UL/FM, AWWA, ISO et.al. They are important because they ensure that the valve has been built to a given standard so the user can be assured they meet approval for such things as low lead content, bacterial growth tests, functional tests etc.
Q 9 Do you have local and factory support?
Make sure there is someone in the area that is factory trained and available to come out and assist when you have questions or problems. This sounds like a given but it&#;s best to ensure the local agent will in fact be there for you when you need him. When a valve fails, timing is usually of the essence so you should know whom to call prior to such an event.
Q 10 Is the valve solution offered able to handle future needs?
In the world of &#;low bid wins&#;, a supplier may be tempted to squeeze as small a valve as possible into the application in order to reduce price. Make sure that the offered solution will supply your needs for the foreseeable future without the burden and additional cost of having to change a valve in a couple of years.
Flow control is an integral part of all industries, such as in chemical plants, power stations, food factories, dyeing and finishing plants, or other factories, flow control is an essential part of process control. Flow controls meanings to control of the flow rate of the medium in an adjustable range according to the process requirements. For example, flow control may be utilized in the chemical industry to manage the flow of liquids between tanks or reactors during the manufacturing process. In an oil and gas plant, flow control may be used to control the flow of fluids through pipelines or to measure the amount of oil or gas being extracted.
Usually, this function is required flow control valves, which regulate the capacity of the fluid or gas in the pipeline and ensure smooth and safe operation. In this article, we will explore the different types of flow control valves, their applications, and the common problems associated with their use.
Introduction of Flow Control Valve
Flow control valves play a key role in regulating the flow of fluids and gases through pipelines, and if you walk into a plant, you can find flow control valves everywhere in the equipment, and they ensure that processes run efficiently and safely. Flow control valves can be found in a variety of industries such as textile mills, water treatment plants, chemical plants, refineries, and power plants. These valves offer several benefits, including improved process efficiency, precise control, reduced energy consumption, and enhanced safety measures.
control valves in food and beverage application
Types of Flow Controls
Globe valves are used for regulating fluid flow and can be found in various configurations, such as on/off globe control valves, single-seated globe control valves, double-seated control globe valves, 3-way globe control valves, and y-type globe valves.
three-way control valves
Ball valves offer excellent shut-off capabilities and are commonly used in applications where tight sealing is required.
ball valve animation
Butterfly valves are designed for controlling the flow of fluids in pipelines and are known for their compact design and ease of operation.
butterfly valve gif
Check valves prevent fluid flow in the reverse direction, ensuring that processes run smoothly and efficiently.
api check valve
5. Automatic Recirculation Valves (ARVs)
ARVs protect pumps from damage by maintaining a minimum flow rate even when the demand for fluid decreases.
6. Diaphragm Valves
Diaphragm valves use a flexible diaphragm to control fluid flow, making them suitable for use in sanitary applications or with abrasive and corrosive materials.
7. Pinch Valves
Pinch valves are designed to control the flow of fluids or gases in pipelines by pinching a flexible tube or sleeve. They are often used in industries such as wastewater treatment, mining, and food processing.
8. Pressure Reducing Valves
Pressure reducing valves regulate the pressure of a fluid or gas by reducing it to a specific set point.
9. Control Valves with Actuators
Valves such as pneumatic angle type control valves and electric temperature control valves are equipped with actuators to enable remote or automated control of fluid flow.
Flow Controls Applications
Flow control valves are used in various industries and applications, including:
Common Questions For Flow Controls
1. How do I select the right flow control valve for my application?
To select the right flow control valve for your applications, we need to consider many processing parameters, which include type of fluid or gas, operation temperature, operation pressure, desired flow rate, pressure drop, or differential pressure, control method, mode of operation and the desired level of control accuracy. Correct sizing not only reduces unnecessary downtime for maintenance for the end user, but also greatly accelerates productivity and accuracy. You can ask for a free consultation with THINKTANK to ensure the right selection.
2. What are the differences between manual and automated flow control valves?
Manual flow control valves require manual adjustment to regulate fluid flow, while automatic valves require the use of actuators such as pneumatic or electric to control fluid flow, via remote signals, or to adjust the valve position according to specific control parameters. You can find these different valves in the following pictures.
If you want to learn more, please visit our website Fluid Control Solutions.
6inch 300lb cf8 control valve manufacturerhandle control valve
Automatic valves are suitable for applications that require precise control, remote operation, or integration with control systems. In modern industry, automatic valves are being used more and more widely in production processes, not only to improve the efficiency of production, precise control, and greater energy savings.
3. How do I maintain flow control valves?
Proper routine maintenance job of flow control valves includes periodic inspections for shell leaks, inner leaks, seals, signals, correct actuator action, and routine valve cleaning and lubrication. In addition, we should replace worn or damaged parts as needed to ensure optimum performance and extend the life of the flow control valve. The end-users need to follow the manufacturer&#;s guidelines and recommended maintenance schedule, which is essential to maintain valve efficiency and prevent unexpected failures. If you don&#;t have the manual book or maintenance book in hand, you can contact the equipment factory to ask them to send it again. Every single valve from THINKTANK will have a 100% test and inspection before shipment, ensuring the reliable quality of flow control valves. You can surely no worries about the quality and service.
4. How do flow control valves affect energy efficiency?
Flow control valves provide precise control of the flow of fluid or gas in a system. The change of flow or pressure after the valve is controlled by the flow area of the valve core through which the fluid or gas passes. Flow control valves can improve industrial energy efficiency mainly through three aspects.
One is to reduce unnecessary energy consumption due to system pressure drop.
We know that when fluid or gas passes through a pipeline or system without a flow control valve, the flow will pass elbows to change direction in the pipeline, or generate friction with the pipeline wall and other reasons, so it will cause a pressure drop in the entire system, because the loss of fluid energy. The pressure drop not only causes energy loss but also wasted a lot of energy and power.
Flow control valves can help reduce pressure drops by regulating the flow capacity, and make sure fluid or gas passes through the system at a consistent pressure. By maintaining a certain pressure value, no need for much energy is required running the entire processing system.
The second is to improve the control of fluid or gas flow in the system.
Flow control valves can ensure that only the required amount of fluid or gas is used at any given time, precisely controlling the flow parameter value, which prevents overuse and wasted energy, resulting in significant energy savings.
Third, flow control valves can help improve energy efficiency by increasing the overall efficiency of the system.
For example, if a flow control valve works in an HVAC system, it can regulate the flow of water through heating and cooling circuits, maintaining the desired temperature and improving energy efficiency while optimizing heat transfer. It&#;s more and more important for end-users save costs during production efficiency. Standing for the customer position to thinking of the market is very valve manufacturer need to be consideration.
5. What is meant by flow control?
Flow control is the process of regulating the flow capacity or volume of a fluid, gas, or steam in a piping system. It involves the use of flow control valves and other devices to manage the flow of the medium to achieve the desired output. Welcome to choose THINKTANK as your reliable partner of flow control valves.
6. What is an example of flow control?
We can list 3 types of different valves to achieve flow controls.
- If using pressure reducing valve to control flow, it regulates the flow of fluid to reduce the downstream pressure range to a desired value.
- If using pneumatic globe type control valve to control flow capacity, the input signals from the controller can directly regulate the valve opening to the precision flow rate needed.
- If using flow level control valve, through the height of the liquid level ball, the opening level of the valve is mechanically controlled.
7. How does flow control system work?
Flow control systems are designed to modulate the process flow rate/capacity of fluids or gases in an industrial system. Based on different applications and types of flow control systems on-site, the operating principles may vary in design.
Generally, a standard flow control system consists of 4 key components.
- Flow Control Valve: Flow control valve is the final component to directly control the pressure or flow rate, in case to meet the desired value in the system. There are many types of flow control valves, such as ball type, butterfly type, globe type, needle type and plug type etc. These valves can be operated by pneumatic actuator, electric actuator, or handle/handwheel.
- Flow Sensors: Flow sensors are used to measure the flow of fluid or gas through a system. Usually, when the flow sensors collect the data from the processing, it will send it to the controller, and the controller will according to the value release a signal to the flow control valve, in case to maintain the desired flow rate by the valve opening or positioning.
- Controllers: Based on the above paragraph, we know the controller is responsible for receiving feedback from the flow sensor and adjusting the opening of the flow control valve as needed. Controllers can use proportional control algorithms to ensure consistent flow, even in the face of changing pressure, temperature, or flow rate, it also can immediately respond. If you need assistance with your application, please just feel free to contact us for a free consultation.
- Pipes: Pipes in the flow control systems are designed to move fluid or gas through the system, it&#;s very common to see them everywhere in the factory. From a source like a storage tank to the destination, such as an industrial process. There are many standards for pipes, make sure it is right for the customer required, and also pay more attention to the standards of pipe flange, and match flanges for flanges of flow control valves.
8. What is the best control of flow?
We need to based on a variety of processing parameters to design the best control of flow solution for customers. Deeply knowing the specific requirements of the system running is very important for professional valve manufacturers, like THINKTANK. It will help us to design and provide precision and control systems for the desired levels as users need.
Here we will introduce the most 4 simple control of flow type systems for your reference.
1. Proportional Control
This type of flow control adjusts the flow rate in proportion to changes in the input signal, such as 4-20mA, 0-10V, or 3-15psi signal. For example, if the input signal is 50%, the response flow rate of the control valve is just adjusted to 50% of the maximum capacity. Proportional control is often used for the high level of accuracy of control systems.
2. On/Off Control
In an on/off control system, the flow control valve is either fully open or fully closed based on the input signal. This type of control is less precise than proportional control but can be simpler and less expensive to implement.
3. PID Control
PID control is a type of proportional control that also takes into account the integral and derivative components of the input signal. The proportional component adjusts the flow rate in proportion to changes in the input signal, while the integral and derivative components help to reduce the &#;overshoot&#; and &#;undershoot&#; that can occur with proportional control. PID control can offer a good balance of precision and simplicity.
4. Flow Limiting Devices
Flow limiting devices are passive devices (such as orifices, flow nozzles, and ventures) that are designed to limit the flow rate of a fluid or gas. These devices can be effective in applications where a fixed flow rate is required and no active control is necessary.
Ultimately, the best control of flow for a particular application will depend on the unique requirements of the system and will take into account factors such as precision, accuracy, cost, and ease of use. A qualified engineer or technician can help to determine the optimal flow control solution based on these factors.
9. What are the 3 types of control flow?
The three types of control flow in computer programming are:
1. Sequential Control Flow
This type of control flow is the simplest and most straightforward. Programs with sequential control flow execute one instruction after the next, in the order that they are written. There is no branching or looping, and each instruction is executed exactly once.
2. Selection Control Flow
In selection control flow, a program chooses between two or more paths based on some condition. This is typically accomplished using if-else statements, which allow the program to execute one block of code if a condition is true, and another block of code if the condition is false. Switch statements are another example of selection control flow, allowing programs to choose between multiple options based on the value of a variable.
3. Iteration Control Flow
Iteration control flow involves repeating a block of code multiple times, either a fixed number of times or until a certain condition is met. This is typically accomplished using loops, such as while loops or for loops, that allow the program to execute a block of code multiple times with different input values.
These three types of control flow are fundamental to most programming languages, and mastering their use is essential to becoming a skilled programmer. By combining sequential, selection, and iteration control flows, programmers can create complex systems that can perform a wide range of tasks.
10. What are the two types of flow control?
The two types of flow control are open-loop and closed-loop control. Open-loop control is a non-feedback system where the output is not used to regulate the input, while closed-loop control is a feedback system where the output is used to regulate the input to maintain a desired output.
open loop control systemclosed-loop control system
11. When should I use flow control?
Flow control should be used when it is necessary to regulate the flow rate or volume of a fluid, gas, or steam to achieve a desired output. It is commonly used in industrial processes, such as chemical and petrochemical plants, food and beverage production, and water treatment facilities. Here are 4 conditions you may consider for using flow control in programming.
- You want your program to respond differently based on certain conditions or events. For example, you might use an if statement to output a different message to the user depending on whether their input meets certain criteria.
- You want your program to execute certain values repeatedly until a certain condition is met. This is typically done using loops, which allow you to run a block of code multiple times with different input values.
- You want to handle errors or unexpected events in your program. This can be done using exception handling, which allows you to catch and handle different types of program errors, such as invalid input or data type errors.
- You want to optimize the efficiency of your code. By using flow control constructs such as loops or switch statements, you can reduce the amount of code you need to write and make your code more efficient by avoiding unnecessary computations or operations.
12. Where is flow control needed?
Flow control is needed in any application where the flow rate or volume of a fluid, gas, or steam needs to be regulated. It is used in various industries, including oil and gas, power generation, water and wastewater treatment, and food and beverage production.
13. What is flow control used to prevent?
Flow control is used to prevent a range of issues, such as overpressure, overheating, cavitation, erosion, and water hammer, which can cause damage to piping systems, valves, and other components.
14. What is the benefit of flow control?
The benefits of flow control include improved efficiency, accuracy, and reliability in controlling the flow rate or volume of a fluid, gas, or steam. It can also reduce operating costs, improve product quality, and enhance safety by preventing damage to piping systems and components.
15. What are the reasons for flow control?
The reasons for flow control vary depending on the specific application and requirements. Some common reasons include ensuring safety and reliability, improving efficiency and accuracy, meeting regulatory requirements, and enhancing product quality.
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