Butterfly Valves & Controls

Butterfly Control Valves

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Introduction

Butterfly control valves are quarter-turn valves that use a metal disc to control fluid flow through a pipeline. The disc is positioned perpendicular to the flow, and when the valve is rotated, the disc opens or closes to regulate the fluid flow. Butterfly control valves are widely used in various industries for flow control and pressure regulation. They offer several advantages over other valves, including low cost, quick operation, and high flow capacity. As a result, butterfly control valves are commonly used in HVAC systems, water treatment and distribution plants, chemical processing, and other industrial applications.

This article aims to provide a comprehensive overview of butterfly control valves, including their design, types, working principle, advantages and disadvantages, applications, selection and sizing, and maintenance and troubleshooting. In addition, this article aims to help engineers, technicians, and other professionals understand the key aspects of butterfly control valves and make informed decisions when selecting and operating these valves.

Design and Components of Butterfly Control Valves

A butterfly control valve is made up of various components such as the body, disc, stem, seat, and actuator. We will discuss these more in depth below.

• Operation of Butterfly Control Valves
  • The operation of butterfly control valves is relatively simple. The disc is mounted on the stem and rotates on a central axis to control fluid flow through the valve. When the valve is fully open, the disc is positioned parallel to the flow, allowing the fluid to flow freely through the valve. When the valve is closed, the disc is positioned perpendicular to the flow, blocking the fluid flow. The disc can also be positioned at any angle between fully open and fully closed to regulate the fluid flow.
• Body
  • The body of a butterfly control valve is typically made of cast iron, ductile iron, carbon steel, stainless steel, or other materials suitable for the application. The body is designed to withstand the pressure and temperature of the fluid flowing through the valve. In addition, the body is usually lightweight and compact, making butterfly control valves suitable for applications with limited space.
• Disc
  • The disc of a butterfly control valve is a thin, circular metal plate that rotates on a central axis. Depending on the application, the disc can be made of various materials, such as stainless steel, aluminum, or plastic. The disc is mounted on the stem and rotates between two seats to control the fluid flow.
• Stem
  • The stem of a butterfly control valve connects the disc to the actuator. It is a cylindrical metal rod that extends through the valve’s body. The stem is designed to withstand the torque the actuator applies and transmit the actuator’s rotation to the disc.
• Seat
  • The seat of a butterfly control valve is the surface against which the disc seals to control the fluid flow. The seat is usually made of a soft material, such as rubber or Teflon™, to provide a tight seal and prevent leakage. The seat is located on the valve’s body and is designed to withstand the pressure and temperature of the fluid flowing through the valve.
• Actuator
  • The actuator of a butterfly control valve is the component that rotates the disc to control the fluid flow. The actuator can be manual or automatic, depending on the application. Manual actuators are typically hand-operated, while automatic actuators can be pneumatic, electric, or hydraulic. The actuator is connected to the stem and applies torque to rotate the disc to the desired position. The actuator can also be used to regulate the speed of the disc rotation and to provide feedback on the position of the disc.

Types of Butterfly Control Valves

Butterfly control valves come in various types, each suite for a specific application. We discuss the different types of butterfly control valves below.

• Wafer Type
  • Wafer-type butterfly control valves are designed to fit between flanges in a pipeline. They are lightweight and compact, making them suitable for applications with limited space. Wafer-type butterfly control valves do not have flanges but holes that align with the bolt holes on the flanges to secure the valve in place. They are typically less expensive than other butterfly control valves and are commonly used in HVAC systems, water treatment and distribution plants, and other industrial applications.
• Lug Type
  • Lug-type butterfly control valves have threaded inserts on the valve body that allow the valve to be bolted to the pipeline. The threaded inserts are located on the valve body, making them suitable for applications where the valve or downstream pipeline needs to be removed without affecting the pipeline. Lug-type butterfly control valves are more expensive than wafer-type valves, but they provide a secure connection to the pipeline. They are commonly used in chemical processing and oil and gas applications.
• Flanged Type
  • Flanged-type butterfly control valves have flanges on the valve body that allow them to be bolted to the pipeline. The flanges provide a secure connection to the pipeline and are suitable for applications with high pressure and temperature. Flanged-type butterfly control valves are more expensive than wafer and lug-type valves, but they provide a secure and leak-free connection to the pipeline. They are commonly used in chemical processing, power generation, and oil and gas applications.

Selection and Sizing of Butterfly Control Valves

The proper selection and sizing of butterfly control valves are essential for efficient and reliable operation. A well-designed and properly sized butterfly control valve can precisely control fluid flow and temperature, resulting in increased efficiency and cost savings.

• Valve Sizing
  • Proper valve sizing is critical for ensuring the efficient operation and longevity of the butterfly control valve. The valve size is determined based on the flow rate, pressure, and temperature of the fluid being controlled. The valve size should be selected to provide sufficient flow capacity while maintaining the desired level of control. A undersized valve can cause excessive pressure drop, cavitation, and erosion, while an oversized valve can result in poor control and unnecessary expense. Typically a Butterfly Valve has its best control in the 20-80% opening
• Choosing the Right Actuator
  • The actuator is an essential component of the butterfly control valve, as it controls the disc’s position. Depending on the application requirements, the actuator can be either pneumatic, electric, or hydraulic. The actuator selection is based on the availability of utilities and preferences. Pneumatic, electric and hydraulic actuators are used for all sizes of valves.
• Material Selection
  • The selection of materials for butterfly control valves is critical for ensuring durability and longevity. The materials used in the valve body, disc, stem, and seat should be compatible with the fluid being controlled and the temperature and pressure conditions. The valve body and disc can be made of carbon steel, stainless steel, or exotic alloys, while the seat can be made of soft material, such as rubber or Teflon™. The stem can be made of materials such as stainless steel, and the actuator can be made of materials such as aluminum or stainless steel.

Advantages of Butterfly Control Valves

Butterfly control valves have several advantages over other types of control valves. Some of these advantages include the following:

• Space Saving
  • Butterfly control valves have a compact design that allows them to be installed in tight spaces where other valves may not fit. They are also lightweight and easy to install, which makes them an ideal choice for applications with limited space.
• Low Cost
  • Butterfly control valves are relatively inexpensive compared to other control valves. They have fewer parts, making them easier to manufacture, install, and maintain. This makes them an attractive choice for applications where cost is a significant factor.
• Low Maintenance
  • Butterfly control valves require minimal maintenance due to their simple design. They have fewer moving parts, making them less prone to wear and tear. This reduces the need for frequent maintenance and replacement of parts, resulting in lower overall maintenance costs.
• Quick Open and Close
  • Butterfly control valves can be opened and closed quickly, making them an ideal choice for applications requiring fast response times. This can be particularly important in emergencies where rapid shut off of a fluid is required.
• High-Capacity Flow
  • Butterfly control valves can handle a high-capacity flow of fluids due to their thin disc surface area. This makes them an ideal choice for applications where high flow rates are required, such as in water treatment and distribution plants and HVAC systems.

Disadvantages of Butterfly Control Valves

While butterfly control valves have several advantages, some limitations should be considered. Some of these disadvantages include the following:

• Limited Temperature Range
  • Rubber seated Butterfly control valves have a limited temperature range, which can be a disadvantage in some applications. For example, they are typically unsuitable for use with high-temperature fluids, as the materials used in their construction may not withstand the heat. Metal seated Butterfly Valves however, can withstand temperatures to F
• Limited Pressure Range
  • Rubber Seated Butterfly control valves have a limited pressure range, which can also be a disadvantage in some applications. For example, they may not be suitable for high-pressure fluids, as the valve body and disc may not withstand the pressure.
  • Steel Butterfly Valves are available 150-900# ANSI( psig)
• Not Suitable for Slurry Applications
  • Butterfly control valves are not suitable for use with slurry applications, as the disc can become clogged with solids, which can impede its movement and result in poor control. Slurry applications typically require more robust construction and design valves, such as knife gate valves full port ball valves or pinch valves.

In summary, butterfly control valves offer several advantages, but they also have some limitations that should be considered. These include a limited temperature and pressure range and the unsuitability for slurry applications. However, these limitations can be mitigated by selecting the appropriate materials and design for the application.

Applications of Butterfly Control Valves

Butterfly control valves are widely used in various industries due to their compact design, low cost, and quick operation. Some common applications of butterfly control valves include:

• HVAC Systems
  • Butterfly control valves are commonly used in HVAC systems to regulate air and water flow. They are particularly useful in large buildings requiring limited space and a high-capacity flow.
• Chemical Industry
  • Butterfly control valves are also commonly used in the chemical industry to control the flow of various chemicals. They are suitable for use with various chemicals and can handle corrosive fluids.
• Water Treatment and Distribution Plants
  • Butterfly control valves are commonly used in water treatment plants to regulate water flow. They are particularly useful in applications requiring large flow rates, such as water distribution systems.
• Food and Beverage Industry
  • Butterfly control valves are also commonly used in the food and beverage industry to control the flow of liquids, such as beverages, dairy products, and sauces. They are suitable for use with food-grade materials and are easy to clean, which makes them an ideal choice for hygienic applications.
• Flow Control
  • Butterfly control valves are used for flow control in various applications. The disc can be positioned at any angle to regulate the fluid flow, providing precise control over the flow rate. The high-capacity flow of butterfly control valves makes them suitable for applications with large flow rates.
• Temperature Control
  • Butterfly control valves are also used for temperature control in some applications. The disc can be positioned to adjust the amount of fluid flowing through the valve, which can affect the temperature of the fluid. In some applications, butterfly control valves are used with other temperature control devices, such as heat exchangers or cooling towers, to maintain the desired temperature range. However, butterfly control valves have a limited temperature range and are unsuitable for applications with extreme temperatures.

Maintenance and Troubleshooting of Butterfly Control Valves

Regular maintenance and troubleshooting are essential to ensure the proper functioning of butterfly control valves. Some of the key maintenance and troubleshooting considerations for butterfly control valves include:

• Regular Inspection
  • Regular inspection of butterfly control valves is important to identify any potential issues before they become major problems. This includes inspecting the valve body, disc, stem, seat, and actuator for signs of wear and tear or damage.
• Lubrication
  • This normally not a requirement for Butterfly Valves however pneumatic actuators require lubricated air
• Common Problems and Solutions
  • Some common problems with butterfly control valves include leakage, poor control, and sticking. These issues can often be resolved through troubleshooting and maintenance activities, such as adjusting the packing, cleaning the valve body and disc, or replacing the actuator.

Conclusion

Butterfly control valves are an important control valve widely used in various industrial applications. They are compact, cost-effective, and provide high-capacity flow regulation. In this article, we have discussed the design and components of butterfly control valves, types of butterfly control valves, advantages and disadvantages, applications, selection and sizing, and maintenance and troubleshooting.

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Flow control device

A butterfly valve is a valve that isolates or regulates the flow of a fluid. The closing mechanism is a disk that rotates.

Principle of operation

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Operation is similar to that of a ball valve, which allows for quick shut off. Butterfly valves are generally favored because they cost less than other valve designs, and are lighter weight so they need less support. The disc is positioned in the center of the pipe. A rod passes through the disc to an actuator on the outside of the valve. Rotating the actuator turns the disc either parallel or perpendicular to the flow. Unlike a ball valve, the disc is always present within the flow, so it induces a pressure drop, even when open.

A butterfly valve is from a family of valves called quarter-turn valves. In operation, the valve is fully open or closed when the disc is rotated a quarter turn. The "butterfly" is a metal disc mounted on a rod. When the valve is closed, the disc is turned so that it completely blocks off the passageway. When the valve is fully open, the disc is rotated a quarter turn so that it allows an almost unrestricted passage of the fluid. The valve may also be opened incrementally to throttle flow.

There are different kinds of butterfly valves, each adapted for different pressures and different usage. The zero-offset butterfly valve, which uses the flexibility of rubber, has the lowest pressure rating. The high-performance double offset butterfly valve, used in slightly higher-pressure systems, is offset from the center line of the disc seat and body seal (offset one), and the center line of the bore (offset two). This creates a cam action during operation to lift the seat out of the seal resulting in less friction than is created in the zero offset design and decreases its tendency to wear. The valve best suited for high-pressure systems is the triple offset butterfly valve. In this valve, the disc seat contact axis is offset, which acts to virtually eliminate sliding contact between disc and seat. In the case of triple offset valves the seat is made of metal so that it can be machined such as to achieve a bubble-tight shut-off when in contact with the disc.

Types

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1. Concentric butterfly valves – this type of valve has a resilient rubber seat with a metal disc.
2. Doubly-eccentric butterfly valves (high-performance butterfly valves or double-offset butterfly valves) – different type of materials is used for seat and disc.
3. Triply-eccentric butterfly valves (triple-offset butterfly valves) – the seats are either laminated or solid metal seat design.
4. Butterfly valve with actuator electric valve - An electrically actuated butterfly valve is a quarter-turn valve controlled by an electric motor. It offers fast and precise flow regulation, remote operation, and versatility for various applications.

Wafer-style butterfly valve

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The wafer style butterfly valve is designed to maintain a seal against bi-directional pressure differential to prevent any backflow in systems designed for unidirectional flow. It accomplishes this with a tightly fitting seal; i.e., gasket, precision machined, and a flat valve face on the upstream and downstream sides of the valve.the drawback is that wafer butterfly valves only have a small flow control range. The pressure drop across wafer butterfly valves may be greater. Wafer butterfly valves are prone to clogging due to their design.[1]

Lug-style butterfly valve

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Lug-style valves have threaded inserts at both sides of the valve body. This allows them to be installed into a system using two sets of bolts and no nuts. The valve is installed between two flanges using a separate set of bolts for each flange. This setup permits either side of the piping system to be disconnected without disturbing the other side.

A lug-style butterfly valve used in dead end service generally has a reduced pressure rating. For example, a lug-style butterfly valve mounted between two flanges has a 1,000 kPa (150 psi) pressure rating. The same valve mounted with one flange, in dead end service, has a 520 kPa (75 psi) rating. Lugged valves are extremely resistant to chemicals and solvents and can handle temperatures up to 200 °C, which makes it a versatile solution.

Rotary valve

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Rotary valves constitute a derivation of the general butterfly valves and are used mainly in powder processing industries. Instead of being flat, the butterfly is equipped with pockets. When closed, it acts exactly like a butterfly valve and is tight. But when it is in the rotation, the pockets allow dropping a defined amount of solids,[2] which makes the valve suitable for dosing bulk product by gravity. Such valves are usually of small size (less than 300 mm), pneumatically activated and rotate 180 degrees back and forth.

Use in industry

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In the pharmaceutical, chemical, and food industries, a butterfly valve is used to interrupt product flow (solid, liquid, gas) within the process.[3] The valves used in these industries are usually manufactured according to cGMP guidelines (current good manufacturing practice). Butterfly valves generally replaced ball valves in many industries, particularly petroleum, due to lower cost and ease of installation, but pipelines containing butterfly valves cannot be 'pigged' for cleaning.

History

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The butterfly valve has been in use since the late 18th century. James Watt used a butterfly valve in his steam engine prototypes. With advances in material manufacturing and technology, butterfly valves could be made smaller and withstand more-extreme temperatures. After World War II, synthetic rubbers were used in the sealer members, allowing the butterfly valve to be used in many more industries.[4] In James E. Hemphill patented an improvement to the butterfly valve, reducing the hydrodynamic torque needed to change the output of the valve.[5]

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Images

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• Cast iron butterfly valve
• Cast iron butterfly valve
• Large butterfly valve
• Butterfly valve DN

See also

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