By Rich Merritt, Senior Technical Editor
CONTROL VALVES, regulators and actuators are one of the few products that the Third World has not been able to reduce to a commodity, so traditional valve manufacturers still have a chance to keep their business. It appears vendors are maintaining their edge through electronic technology in the form of built-in controllers, networks, fieldbuses and software.
As you can see in the roundup that follows, new valve products sport HART, fieldbus, DeviceNet and similar communications along with traditional 4-20 mA. Some have built-in controllers that can diagnose valve and positioner health. These advances might help account for increasing control valve sales on the world market.
The worldwide control valve market totaled nearly $2.9 billion in 2003 and will reach nearly $3.4 billion by the end of 2008, expanding at an annual rate of about 3%, according to "Control Valve Worldwide Outlook," a study by the ARC Advisory Group.
"Long-term business prospects for control valve suppliers look reasonably bright due to MRO business opportunities in developed regions and new projects' business in developing countries," says senior analyst Dave Clayton, author of the study. From a regional perspective, most of the growth over the next five years will come from Asian countries, such as India and China. Russia is also a promising market.
The share of North America in the worldwide control valve market is decreasing, the study says, and the trend will continue over the forecast period as developing countries continue expanding their manufacturing base.
The world market for all industrial valves will rise to $5l billion in 2005 from just over $41 billion in 2001, says “Valves: World Market,” a study by McIlvaine. The oil and gas sector is the largest. This will grow from $11 billion in 2001 to $13 billion in 2005. The second largest sector is power, followed by chemical, refining, municipal water, and municipal wastewater.
As usual, the market researchers disagree. ARC says the world market for control valves will be $3.4 billion by 2008, but McIlvaine says automatic regulation and control valves sales are projected to reach $12 billion this year. Gate and globe valve sales will exceed $9 billion while ball valve sales in 2005 will be just under $7 billion. Three other categories (butterfly, industrial plug, and miscellaneous) comprise the balance of the market, says McIlvaine.
If you see “more info at controlglobal.com” in the product description, it means we had more information than would fit into the product writeup, so we included it in the writeup that appears on our web site. If you want to see more about these products, go to controlglobal.com, scroll down to Site Highlights, and click on the Roundup section.
Valves, Actuators and Positioners Plug In
Smart Positioner Cuts Air
In balanced conditions, the Sipart PS2 valve positioner consumes virtually no air, saving users $900/year per valve compared to using the company’s conventional smart positioners. The positioner moves the actuator to a valve position corresponding to the setpoint. It can self-diagnose system changes and optimize the tuning parameters to maintain valve performance, even with changes in actuator supply pressure and valve friction. Siemens Energy & Automation; 215/646-7400; www.sea.siemens.com/ia
Digital Valve Controllers
Fisher Fieldvue DVC2000 Series digital valve controller meets NAMUR standards IEC60534-6-1 and IEC60534-6-2, and can be mounted on Fisher and other brand actuators on linear and rotary valves. It has a two stage, pre-amplifier that multiplies small changes in the pneumatic signal, a digital tuning algorithm, and performs valve diagnostics. Fisher/Emerson; www.emersonprocess.com
The PMV D3 digital valve positioner for control of linear and rotary control valves communicates via Foundation fieldbus, 4-20 mA analog, HART, and Profibus PA. Its user interface employs a menu structure similar to cell phone menus, so the positioner can be configured manually via its keypad, through a HART handheld device, or from a fieldbus system. Flowserve; 281/ 292-7500; www.flowserve.com.
Smart and Safe
The microprocessor-controlled Type 8635 process controller/positioner for linear and rotary control valves is intrinsically safe for use in FM Class 1 Div 1 environments. The user can program all critical interface options via a three-key HMI with a plain-text display located within the IP 65 housing, or through HART or Profibus PA communication protocols. Burkert; 800/325-1405; www.burkert-usa.com.
Models in the Series 3730 include the 3730-0 low-cost positioner for globe valves, 3730-1 for all globe and rotary applications, and 3730-2, with a microprocessor controller. Options include HART, Profibus and Foundation fieldbus communications, valve diagnostic software, and explosionproof operation. Valve diagnostics are integrated and supply the information required for predictive maintenance without the need for additional software. Samson Controls; 281/383-3677 x279; www.samsoncontrols.com
Absolute Position Feedback linear actuator sensor provides analog feedback to the controller or PLC to determine actual load position. The option is available for the company’s BC3 pneumatic and B3S electric series actuators, and can be ordered in incremental stroke lengths from 2-156 in. An analog signal of 0 to +10Vdc or –10 to +10 Vdc can be selected. Tol-O-Matic; 800/328-2174; www.tolomatic.com
The IQT electric, quarter-turn, non-intrusive valve actuator is double sealed to provide a watertight enclosure. It can be connected to Industrial Ethernet, Fieldbus, Modbus, Profibus, DeviceNet, and PakScan systems. Users can configure and set the actuator without removing its covers by using an intrinsically safe, point-and-shoot hand-setting tool. Options include three-phase, DC, or single-phase operation, and on-board data logger. Rotork Controls; 585/328-1550; www.rotork.com
The Contrac intelligent electric modulating rotary actuator provides 90-degree rotary movement for such applications as dampers and butterfly valves. The actuator transfers torque via a lever/linkage bar assembly, or it can be directly coupled to the driven shaft. During continuous positioning the power electronics unit varies the motor torque without stepping until the actuator force and the restoring process forces are balanced. ABB Automation Technology Products; 215/674-6580; www.us.abb.com
Stepping Motor Valves Stay Put
For gases or liquids, these two-way metering valves use high precision stepping motors to drive the valve spindles. Resolution of the stepping motor driven needles is 0.0005 in./step, and valves stay in position when de-energized. Advantages over the company’s solenoid-operated valves include cool operations, extremely fine resolution, very low differential pressures and high operating pressures. Low differential pressure valves may be operated continuously in a 100% duty cycle. Aalborg; 800/866.3837; www.aalborg.com
Valve Sensors Do DeviceNet
The NI 4-DSU35-2DNETX5-H1150 solid-state sensor is DeviceNet compatible with standard M12 euro fast connections. The sensor monitors the position of rotary actuators, provides open and closed position on most 90 deg actuators for direct valve control, and gives the user both a visual and electrical position indication. It can be mounted on several different actuator sizes without requiring additional adapters or spacer plates. Turck; 800/544-7769; www.turck.com
Ball Valve is Quite a Character
Type 546 characterized ball valve creates a gradual change in flow rather than the sudden change typical with the company’s traditional ball valve styles. With each incremental valve turn, the flow increases or decreases linearly. It has all-plastic construction and is available in 1/2–2 in. sizes. Material options include PVC, CPVC, polypropylene and PVDF, making it suitable for use as a shut-off valve for aggressive media. George Fischer; 800/854-4090; www.us.piping.georgefischer.com
Manifold-mounted solenoid valve simulates a constant flow by using rapid cycling miniature solenoid valves to dispense gradients from multiple fluid streams in precise, repeatable proportions suitable for precision high purity diverting and mixing applications. All ports are positioned on the same side of the manifold, with the common outlet port centered between the inlet ports. Valves are available in PTFE, PEEK and PPS while diaphragm materials are offered in PTFE, EPDM, Viton and perfluoroelastomer. Bio-Chem Valve; 973/263-3001; www.bio-chemvalve.com.
Stainless Steel Valve
The VC-210 Mini-Max corrosion-resistant control valve has a stainless steel investment-cast body with stainless steel trim. The valve is single-seated and bellows sealed to prevent stem leakage. Its pneumatic actuator has a molded Buna-N, two-ply Dacron reinforced diaphragm enclosed in a die-cast aluminum housing and frame. Options include full ported or low flow models, and two- way, direct- or reverse-acting, or three-way valves in sizes from 1/2 to 1 in. Robertshaw Industrial Products; 800/228-7429; www.robertshawindustrial.com.
Clean Ball Valve
For use in pharmaceutical, food, and chemical-processing systems, Series BV3-SS ball valves have a sanitary polish and a cavity filler that reduces product entrapment. The valves are available with either electric or pneumatic actuators. Two-position actuators use the 115 VAC input to drive the valve open or closed, while the modulating actuator accepts a 4 to 20 mA input for infinite valve positioning. Price: from $149.00. Dwyer Instruments; 219/879-8000; www.dwyer-inst.com
Actuator Buckles under Pressure
The Buckling Pin Actuator can be mounted on most quarter turn valves for pressure relief, emergency shutdown, or flow diversion application. It is self actuated, does not need electricity or an air supply for operation, and can be remotely located without fear of operational failure. Rupture Pin Technology; 405/789.1884; www.rupturepin.com.
Pressure Relief Valve
Type E corrosion resistant pressure relief valves have PTFE bellows stem seals, body materials of PVC, PP, PVDF and PTFE, O-Ring seals of EPDM, FKM or PTFE encapsulated FKM, and are available in sizes from 1/4 to 4 in. Drilled to an ANSI B16.5 bolt pattern, the valves can be installed in thermoplastic piping or metal pipelines. The valves are suited for aggressive chemical applications. Asahi/America; 781/321-5409; www.asahi-america.com
Ball Valve is Instrumental
Hi Pro instrumentation ball valve family has two-piece construction that reduces potential leak paths to a minimum, provides ANSI Class 1500 operation, and meets the firesafe requirements of API 607 and BS6755 Part 2. The valve's body end connector thread is fitted with an environmental seal, protecting it from external corrosion attack. Parker Hannifin; 256/881-2040; www.parker.com
Tubing Pinch Valve
Solenoid-operated pinch valves control flow by squeezing tubing closed, making them suitable for contamination-free pharmaceutical and laboratory process applications. Valves operate with tubing that has a durometer rating of 50 or less—such as with C-FLEX or silicone—in sizes L/S 14, 16, 17, and 25. Available in normally closed or normally open configurations. Cole-Parmer Instrument; 800/323-4340; www.coleparmer.com/938.
This remote-mount two-valve manifold has a non-rotating, hardened needle design to minimize seal wear, protect the seat from galling, and promote long service life and leak-tight shutoff. Strong, cold-rolled stem threads are isolated from system media and protected from dirt and dust by a stainless steel shroud. It has 316 stainless steel construction, handles operating pressures up to 6,000 psig at 200 F, and has color-coded valve label rings for easy valve identification. Swagelok; 440/349-5934; www.swagelok.com.
C60 Series regulating valves provide flow from 0 to 40 gpm and can handle pressures from 75 to 2,500 psi, with fluid temperatures up to 200°F. The valves are available in stainless steel, nickel alloy or solid brass and accommodate 0.75 in. to 1.25 in. NPT/BSPT plumbing. When a system discharge is completely closed – such as a closed valve or plugged nozzle – the valve bypasses the total system fluid flow. Wanner Engineering; 612/332-5681; www.hydra-cell.com.