From Steam to Smart Valves: Masoneilan’s Ongoing Story of Excellence

Masoneilan valves have stood at the forefront of industrial valve technology for over a century, building a legacy of engineering excellence that few can match. Founded in 1882 by William B. Mason, the company quickly established a reputation for quality in the emerging field of automatic control valves. By 1931, after acquiring the Neilan Company of California, the firm adopted the Mason-Neilan name—later stylized as Masoneilan—and became synonymous with innovation. 1944, Masoneilan introduced the now-standard flow coefficient (Cv) concept to the industry, a pioneering move that underscored its technical leadership. Today, Masoneilan carries forward this proud heritage as a division of Baker Hughes. The backing of a global energy technology leader provides a powerful platform, but it is Masoneilan’s long-standing commitment to quality and ingenuity that truly drives its success. Masoneilan has exemplified leading technology and responsiveness to market needs for well over a century, earning the trust of engineers and operators worldwide. Masoneilan has come to mean confidence in critical control from the steam age to the digital age.

Innovation has always been at the heart of the Masoneilan story. The company has continually pushed the boundaries of valve design to solve tough engineering challenges. A shining example came in 1968 when Masoneilan introduced the revolutionary Camflex control valve. This was no ordinary product launch: the Camflex created an entirely new category by blending the precise control of a globe valve with smooth rotary motion. The result was a versatile valve design that could replace most control valves in use. Adoption was swift, and more than one million Camflex valves have been installed worldwide, tackling applications from basic water service to severely erosive flows that would compromise lesser valves. The Camflex’s longevity—still going strong after fifty years—testifies to Masoneilan’s forward-thinking approach. It offered more straightforward construction with fewer parts and higher reliability than traditional designs and has withstood the test of time. Masoneilan continued to refine and enhance its product lines over the decades, staying one step ahead of industry needs. The company was among the first to integrate digital instrumentation with control valves, launching smart valve positioners that brought diagnostic intelligence to the field. This spirit of innovation continues today, with new developments to improve efficiency and performance in every aspect of flow control.

One of the significant factors in Masoneilan’s success is its extensive product line. The brand covers a wide range of solutions for critical flow control, including globe control valves, rotary control valves, and severe service valves that handle punishing applications. These specialized designs feature robust trims and engineering that resist cavitation, erosion, and high-pressure drops. They deliver accurate control without sacrificing durability, making them ideal for hot, abrasive, or high-pressure conditions. Masoneilan also offers pressure regulators for maintaining stable inlet or outlet pressures and a comprehensive portfolio of actuators for smooth and responsive valve operation. Engineers can choose from digital valve positioners for advanced monitoring and self-tuning capabilities or pneumatic positioners when a more traditional approach suits the application. Rounding out the lineup, Masoneilan provides isolation and emergency shutdown valves built to operate swiftly and securely during critical events. This comprehensive offering means customers can rely on a single source for all their flow control needs, ensuring compatibility and simplifying procurement.

In Florida and the Caribbean, industrial settings demand rugged equipment that withstands high temperatures, corrosive atmospheres, and constant humidity. Masoneilan meets these demands through rugged designs crafted to perform where other valves fail. Key components feature corrosion-resistant materials, with specialized trims that guard against wear from salt, sand, and chemical exposures. These construction choices in coastal desalination plants or chemical facilities that handle acids translate into a longer service life and fewer unplanned shutdowns. Masoneilan valves do more than tolerate adverse conditions: they excel in maintaining tight sealing and smooth operation year after year. The brand’s engineers also focus on mitigating the effects of noise, vibration, and cavitation. Many Masoneilan products use heavy-duty, cage-guided trims to stabilize moving parts under turbulence. Severe-service valves often include multi-stage pressure letdowns to reduce the risk of cavitation, lessening wear, and cutting noise levels. That combination of ruggedness, precision, and energy dissipation allows Masoneilan products to operate reliably for decades, even under conditions that challenge typical valve designs.

Masoneilan’s broad capabilities and high standards make it a natural choice for many industries in Florida and the Caribbean. Power generation plants in Florida rely on Masoneilan valves to regulate steam flow, feedwater, and other critical functions for smooth turbine operation. In the Caribbean, desalination plants count on Masoneilan’s corrosion-resistant solutions to deliver consistent freshwater supplies under relentless salt spray and humidity. Oil and gas refineries and chemical processing facilities put their trust in Masoneilan valves to accurately control high-pressure, high-temperature flows. These valves provide tight performance in reactors, separators, and furnaces without succumbing to corrosion or erosion, boosting production efficiency while reducing maintenance downtime. Masoneilan’s portfolio also proves essential in maritime applications, from offshore platforms to large commercial ships. Operators depend on the durability and rapid response of emergency shutdown valves, actuators, and control valves to ensure safe operation in some of the most unforgiving conditions on Earth.

From its 19th-century origins to today's leading-edge technologies, Masoneilan has built an unparalleled reputation for quality, innovation, and trusted performance. That legacy continues in Florida and the Caribbean, and beyond, where Masoneilan valves are the go-to choice for challenging climates and demanding industrial processes. Now backed by the global resources of Baker Hughes, the brand offers a powerful blend of engineering expertise and technical support. Plant managers and engineers agree that a Masoneilan valve delivers peace of mind when reliability matters most. Masoneilan stands out for its ability to handle extreme service conditions while maintaining precise, accurate flow control in an era focused on efficiency and uptime. Backed by a heritage of engineering excellence over 140 years, Masoneilan promises to remain a steadfast partner to industries facing the harshest operating environments. Its tradition of reliability, innovation, and proven value continues to drive excellence in power generation, water treatment, oil and gas refining, and countless other applications, both on land and at sea.

Classic Controls
+1 863-644-3642
https://classiccontrols.com

Maximizing Market Penetration: The Need for Skilled Sales Engineers in the Caribbean's Industrial Sector

In the highly specialized field of industrial valves and controls, manufacturers face unique challenges in expanding their market reach, particularly in diverse and geographically dispersed regions like the Caribbean. Partnering with a technically skilled and account-knowledgeable sales engineering agency to cover the entire Caribbean, including key markets such as Puerto Rico, Trinidad & Tobago, Guyana, and Suriname, cannot be overstated. 

Expertise in Local Market Needs

The Caribbean region presents a unique blend of industrial needs driven by sectors such as oil and gas, petrochemicals, power generation, and infrastructure development. Each country within the region has its specific industrial demands, regulatory requirements, and operational challenges. A sales engineering agency with deep technical expertise and localized knowledge can effectively bridge the gap between these market demands and the manufacturer’s product offerings. 

For example, in Trinidad and Tobago, a major player in the oil and gas industry, the need for high-performance, corrosion-resistant valves that can withstand harsh environments is critical. In contrast, countries like Guyana, experiencing rapid growth due to recent oil discoveries, require solutions supporting exploration and new infrastructure development. An agency with technical acumen can guide manufacturers in tailoring their products to meet these diverse needs, ensuring relevance and competitiveness in each market.

Enhancing Customer Relationships

A sales engineering agency that combines technical knowledge with account management skills is invaluable in cultivating and maintaining strong customer relationships. Industrial clients in the Caribbean often require more than just products; they need solutions to complex operational challenges. A technically proficient sales team can engage with these clients at a deeper level, understanding their specific problems and proposing tailored solutions that add real value. 

For instance, in Puerto Rico, where the power generation and manufacturing sectors are significant, clients may require customized valve and control solutions that enhance efficiency and reliability in the face of frequent natural disasters. A knowledgeable sales engineering agency can provide these solutions and offer ongoing support and training, building trust and loyalty with customers.

Navigating Regulatory and Logistical Challenges

The Caribbean region has various regulatory environments, logistical challenges, and import/export complexities. A sales engineering agency with in-depth knowledge of these factors can help manufacturers navigate these hurdles effectively. For example, understanding the certification requirements in Suriname or the importation regulations in Trinidad & Tobago can be the difference between a successful project and costly delays. 

Additionally, logistical challenges such as transportation, warehousing, and distribution across the islands require careful planning and execution. An agency with experience in these areas can ensure that products are delivered on time and within budget, enhancing the manufacturer’s reputation and reliability in the region.

Expanding Market Reach

Finally, a technically skilled and account-knowledgeable sales engineering agency can significantly expand a manufacturer’s market reach in the Caribbean. By leveraging their expertise and local presence, they can identify new opportunities, engage with key stakeholders, and drive growth in markets that may have previously been inaccessible.

For an industrial valve and control manufacturer, partnering with a sales engineering agency with technical expertise and a deep understanding of the Caribbean market is crucial for success. This partnership ensures that the manufacturer’s products are well-represented and effectively sold and positions them as a trusted and reliable solution provider in this diverse and dynamic region.

Classic Controls
+1 863-644-3642
https://classiccontrols.com

Globe, Rotary, and Butterfly Control Valves

Control valves are crucial components in industrial processes, used to regulate the flow of fluids. Different types of control valves offer specific advantages and are suitable for particular applications. Here's a comparison of globe style control valves, rotary control valves, and butterfly control valves:

Globe Style Control Valves

Design and Operation:

These have a linear motion and use a movable disk-type element and a stationary ring seat in a spherical body. The disk can be moved away from the seat (to open) or towards the seat (to close) to regulate the flow.

Advantages:

• Precise control: They are well known for their accurate throttling capabilities.
• Good shut-off capability.
• Wide rangeability (the range of flow rates over which the valve can effectively control).

Disadvantages:

• Higher pressure drop compared to other types of valves.
• Bulky design and requires more space.

Applications:

• Suitable for most processes where precise control is needed.
• Often used in extreme temperature and pressure applications.

Rotary Control Valves

Design and Operation:

These valves rotate a disk or ball, with or without a shaft, within the flow stream to control flow. Common examples include ball valves, v-notch ball valves, and eccentric disk valves.

Advantages:

• Compact design.
• Lower pressure drops compared to globe valves.
• Quick response and faster actuation compared to globe valves.
• Good rangeability.

Disadvantages:

• Less precise control compared to globe valves in some applications.
• Might not provide as tight shut-off as globe valves.

Applications:

• Suitable for applications where quick actuation or less pressure drop is crucial.
• Often used for on/off services or in applications where the media might cause obstruction in other types of valves.

Butterfly Control Valves

Design and Operation:

Consists of a circular disc or plate built onto a rod. When the rod is turned, the disc turns at a right angle to the flow, acting like a dam to stop or start the flow.

Advantages:

• Extremely compact design.
• Economical, especially for larger sizes.
• Low pressure drop.
• Suitable for slurry applications or services with suspended particles.

Disadvantages:

• Not as precise as globe valves for control.
• Might not offer a tight shut-off in certain designs.
• Rangeability is often less than globe or some rotary valves.

Applications:

• Used in cooling water systems, air/gas compressors, and industrial HVAC systems.
• Suitable for applications where tight shut-off isn't critical and where space or cost is a concern.

In choosing the right control valve for a specific application, various factors need to be considered, including the nature of the media, the required flow rate, the allowable pressure drop, the need for tight shut-off, and the degree of control precision. Each type of valve has its own niche in industrial applications, and the selection often depends on trade-offs among these factors.

Classic Controls

(863) 644-3642

https://classiccontrols.com

From South Georgia and Florida, to the Caribbean and Beyond: How Classic Controls Leads in Automation, Industrial Valves and Process Instrumentation

Headquartered in Lakeland, Florida, Classic Controls has established a remarkable reputation in process control instrumentation and industrial valves. The company has strategically partnered with various industries, including water treatment, pharmaceutical, chemical, oil and gas, power generation, and food processing. Serving an expansive geographic area encompassing Southern Georgia, Florida, Puerto Rico, the Caribbean, Trinidad & Tobago, Guyana, and Suriname, Classic Controls is known for its expertise, reliability, and quality service.

Classic Controls has demonstrated its unmatched proficiency by designing and implementing systems that optimize processes, ensuring efficient and smooth operations. Their specialization includes specifying and applying cutting-edge instrumentation and industrial valves that facilitate automation, control, and safety in industrial environments. With an experienced team of skilled professionals, Classic Controls provides state-of-the-art solutions to meet the specific needs of its clients.

Classic Controls understands the critical role of reliable process control instrumentation and industrial valves in water treatment. They apply their vast knowledge and expertise to develop sophisticated systems that ensure water treatment plants' safe, efficient, and reliable operation. By focusing on the precision of water flow and temperature control, Classic Controls delivers clean and safe water across the region.

Classic Controls delivers systems that guarantee rigorous industry quality and safety requirements within the pharmaceutical industry. Implementing robust process control instrumentation ensures the accuracy, repeatability, and consistency required in the drug manufacturing process, playing a significant role in safeguarding public health.

Classic Controls' solutions are instrumental in maintaining operational efficiency, reducing downtime, and ensuring safety when working with chemical, oil and gas, and power generation companies. Their advanced process control systems mitigate risks associated with these industries, providing peace of mind for operators and stakeholders alike.

In the food processing industry, Classic Controls' expertise facilitates precise control over the various steps of the production process, from raw material handling to packaging. This precision, coupled with their stringent quality controls, enables companies to ensure the consistent production of safe, high-quality food products.

Classic Controls' influence extends beyond Florida and Southern Georgia to the Caribbean, where their cutting-edge solutions are integral to the operation of numerous industries. Despite the unique challenges posed by the region's climate and infrastructure, Classic Controls has proved its versatility and adaptability, delivering reliable solutions that enhance productivity and safety.

In conclusion, Classic Controls' dedication to delivering top-tier process control instrumentation and industrial valves has cemented its position as a trusted partner to various industries. Their commitment to quality, safety, and reliability, combined with their in-depth industry knowledge and technical expertise, enables them to provide exceptional solutions to businesses across Southern Georgia, Florida, and the Caribbean. Whether in water treatment, pharmaceuticals, chemical processing, oil and gas, power generation, or food processing, Classic Controls stands as a pillar of excellence in industrial automation and process control.

Industrial Control Valve Primer

There are several industrial control valves, each with unique characteristics and uses. Some common types of control valves include:

Globe valves: Globe valves are typically used for regulating flow in pipelines and are known for their ability to handle high-pressure systems. They consist of a disk that moves up and down to block or allow flow through the valve. Industrial globe valves are mechanical devices that are used to regulate the flow of liquids or gases in a pipe. They consist of a cylindrical body with a disk-shaped element, called the plug or disc, that moves up and down to open and close the valve. The disk is connected to a stem, which is operated by a handwheel, lever or pneumatic or electric actuator. When the stem is turned, it raises or lowers the disk, allowing for the flow of fluid through the valve. Globe valves are typically used in industrial settings, where precise control over the flow of fluids is important. They are known for their durability and reliability and are often used in applications such as steam systems, water treatment plants, and chemical processing facilities.

Butterfly valves: Butterfly valves are used for controlling the flow of fluids in pipelines. They consist of a disk that rotates to block or allow flow through the valve. They are known for their low cost and ease of installation. Butterfly valves are a type of industrial valve that are typically used to regulate the flow of fluids, such as gases, liquids, and slurries, in a pipe. They are called butterfly valves because the mechanism that controls the flow of the fluid is a disc that is mounted on a shaft and rotates like a butterfly's wings.

Some of the key characteristics of industrial butterfly valves include:

• They are relatively compact and lightweight compared to other types of valves, which makes them easy to install and handle.
• They are able to handle a wide range of temperatures and pressures, making them suitable for use in many different industrial applications.
• Butterfly valves are often used in applications where a tight shutoff is required, as they can provide a very tight seal when closed.
• They are typically used in applications where the fluid being controlled is either highly viscous or abrasive, as the design of the valve allows for low-friction operation and reduces the wear on the valve's components.
• Butterfly valves are available in a wide range of sizes and materials, which allows them to be tailored to the specific requirements of a particular application.

Diaphragm valves: Diaphragm valves are used for controlling the flow of fluids in pipelines. They consist of a flexible diaphragm that moves to block or allow flow through the valve. They are often used in applications where the fluid being controlled is corrosive or dirty. Industrial diaphragm valves are valves that use a flexible membrane to control the flow of liquids or gases. The membrane is typically made of rubber or another flexible material and is positioned between the valve body and the valve seat. When the valve is open, the membrane flexes to allow the flow of fluid, and when the valve is closed, the membrane seals against the valve seat to stop the flow. Diaphragm valves are commonly used in industrial piping systems for a variety of applications, such as controlling the flow of chemicals, water, steam, and other liquids and gases. They are often used in situations where the fluid being controlled is corrosive or abrasive, as the flexible membrane helps to prevent damage to the valve body.

Plug valves: Plug valves are used for controlling the flow of fluids in pipelines. They consist of a plug that rotates to block or allow flow through the valve. They are known for their ability to handle high-pressure systems and are often used in applications where the fluid being controlled is viscous. Industrial plug valves are a type of quarter-turn valve that is used in various industrial applications to control the flow of liquids and gases. They are named for the plug-shaped component that is used to open and close the valve. Some of the key characteristics of industrial plug valves include:

• Quarter-turn operation: As mentioned, industrial plug valves are quarter-turn valves, which means they can be opened and closed by rotating the valve handle or stem by 90 degrees. This allows for quick and easy operation of the valve, and is particularly useful in applications where the flow needs to be quickly shut off.
• Plug-shaped component: The core component of an industrial plug valve is the plug, which is a cylindrical piece with a hole through the center. When the plug is rotated to align the hole with the inlet and outlet ports, the valve is open and allows flow. When the plug is rotated so that the hole is perpendicular to the inlet and outlet ports, the valve is closed and blocks flow.
• Various materials and sizes: Industrial plug valves are available in a range of materials, including metal alloys, plastic, and other materials, depending on the specific application and media being controlled. They are also available in a range of sizes to accommodate different flow rates and pressure ratings.
• Multiple sealing options: Industrial plug valves can be equipped with a variety of sealing options, such as soft seats, metal seats, or a combination of both. This allows for better control of the flow and pressure, and can prevent leaks in the system.
• Low-maintenance design: Industrial plug valves are known for their low-maintenance design, which makes them a popular choice for many industrial applications. They have few moving parts and can be easily disassembled and cleaned, reducing downtime and maintenance costs.

Each type of control valve has its own unique advantages and disadvantages, and the best type of valve for a particular application will depend on the specific requirements of the system. Discuss your control valve requirements with professional, skilled application engineers. Classic Controls is available to assist in the application and specification of any valve application for any industrial or commercial process. Call them at 863-644-3642 or visit their website at https://classiccontrols.com.

Control Valve Application Tips

Incorrectly applied or sized control valve may have significant ramifications for operation, production, and, most importantly, safety. 

Here is a brief checklist of things to think about:

1. Control valves are not isolation valves. Don't apply them as such.
2. Always carefully choose the suitable construction material. Consider the valve components that come into contact with the process medium, such as the valve body, seat, and other "wetted" portions. Consider the control valve operational pressure and temperature exposure. Finally, examine the surrounding environment and any corrosives that may arise and affect the outside of the valve. 
3. Place the flow sensor upstream of the control valve.  When the flow sensor is downstream of the control valve, it senses a less stable flow stream created by turbulent flow in the valve cavity. 
4. Consider the degree of control you need and ensure that your valve's design will provide the controllability you require. 
5. Excessive dead-band leads to hunting and poor control. The change of input signal necessary to induce a change in valve position is dead-band. Dead-band is affected by worn or loosely fitting mechanical linkages or a controller setting. It may also be affected by mechanical sensor tolerances, friction in the valve stems and seats, or an undersized actuator. 
6. Think about stiction. Stiction is the propensity of valves that have had very little motion or have not moved at all to "stick." It is usually produced by the valves, packing glands, seats, or the pressure applied to the disk. 
7. Make sure your loop controller is appropriately tuned.  Overshoot, undershoot, and hunting are symptoms of a poorly tuned controller. Check your proportional, integral, and derivative controller settings. Today, employing controllers with powerful, accurate auto-tuning capabilities that have replaced the old-fashioned trial and error loop tuning approach, is relatively simple. 
8. Avoid oversizing your control valve.  Control valves are usually oversized for the flow loop they control. A tiny change in valve position has a considerable influence on flow. If the control valve is too large, only a fraction of its valve travel occurs, causing the valve to hunt, leading to severe wear. Always size a control valve to allow 70-90 percent of travel. 
9. Consider the kind of control valve you're employing and its inherent flow characteristics. Flow properties vary greatly across valve types and their disks (or profiles). The flow characteristic is the change in flow rate in response to a change in valve position. The linear features of globe control valves are preferable, while the non-linear flow characteristics of butterfly and gate valves might pose control issues. Manufacturers add specifically designed disks or flow orifices that provide a custom flow profile to establish a linear flow characteristic via a non-linear control valve.

Classic Controls
https://classiccontrols.com
+1 863-644-3642

Masoneilan™ Control Valves and Smart Valve Positioners

Baker Hughes™ Masoneilan, automated process control solutions, are well-known for their dependability and excellence worldwide. These solutions, including the Masoneilan™ 41005 Series Cage-Guided Globe Valve, are part of the Masoneilan™ valve technology portfolio, which has helped customers maintain smooth operations for over 100 years. 

For all of your valve demands, SVI™ offers industry-leading control and diagnostic solutions. Masoneilan™ pioneered non-contact position sense technology and are well renowned for simple setup, rugged design, and high-performance control in critical service valve and level transmitter applications. SVI™ and the ValVue™ diagnostics software that goes with it are compatible with all significant DCS and plant asset management systems. 

Masoneilan™ digital field instruments save money over their entire lifecycle by simplifying installation and setup, offering industry-leading control performance, and lowering maintenance and support. SVI™ offers high precision HART® and FOUNDATION® Fieldbus valve positioning for control valve and emergency shutdown (ESD) applications. The 12400 DLT enables high precision level output and control for level transmitter applications, enhancing plant efficiency, performance, and safety.

For more information in Florida, Puerto Rico, and the Caribbean, contact Classic Controls. Call them at +1 863-644-3642 or visit their website at https://classiccontrols.com.

Masoneilan Process Control Valve Condensed Catalog

With its breadth of products and services, unequaled global presence and advanced process control expertise, Masoneilan is uniquely positioned to be the leading provider of control valve solutions. For well over a century Masoneilan has been synonymous with innovation, leading technology and responsiveness to market needs.

What Makes Masoneilan Unique

Balanced trim design; Smaller actuators reduce overall assembly size and weight; Heavy cage-guided construction; Heavy guiding of the plug enhances throttling control performance; Reliability & low maintenance; Standard solutions to control noise cavitation & valve leakage; Versatile valve technology; Robust construction; Long-term smooth operation; Optimized process control and high process yields.

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DOWNLOAD THE MASONEILAN PROCESS CONTROL VALVE CONDENSED CATALOG FROM THIS WEB PAGE

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Classic Controls, Inc.
https://classiccontrols.com
863-644-3642

Globe Control Valves

Internal view of globe control valve (Masoneilan)

Globe control valves work differently when compared to gate valves, ball valves, butterfly valves and plug valves in process control applications. They are primarily used to control the flow inside pipes, and are popular in a wide variety of industries. Globe control valves are ideal in situations where precise control is required. They are used to regulate flow in pipelines with a high degree of accuracy by regulating a pressures drop created in the valve body that allows the fluid to pass through the passageway (port) in the valve body. The control valve stem provides linear motion to bi-directionally control flow, opening and closing the valve by changing the distance between valve disc and seat. The flow in the pipeline changes according to the position of the disc lifting from the seat. The movement is controlled through the use of manual operators, or through the use of electric or pneumatic actuators.

Applications of Globe Control Valves 

Globe control valves are used in many different industries, but particularly in the petrochemical and power generation industries on fuel oil pipes, chemical feed systems, steam pipes, as well as cooling water and feedwater systems.  Other industrial applications of globe valve include boiler, main steam vents, and turbine lube oil systems.

Pros

Globe control valves have many advantages that make them preferable over other valve designs. Globe control valves have excellent shut-off and throttling capabilities. In addition, globe valves are easy to maintain and repair compared to other valves.

Cons

Globe control valves have also certain shortcomings. For instance, globe valves have an S-shaped flow pattern (as opposed to a straight-through flow pattern) which creates a significant pressure drop making them unsuitable for applications constant pressure is required.  Another shortcoming of the globe valves is they generally require greater torque to open and close, requiring larger actuators to properly seat the valve.

For more information on industrial globe valves, or any type of industrial valve, contact Classic Controls by calling 863-644-3642 or by visiting https://classiccontrols.com.

Industrial Control Valve Body and Actuator Operation

Control valve (Masoneilan)

The design and operation of industrial control valves  is very important to understand if you work as a process engineer, a plant maintenance person, or if you design process control loops.

Control valves are used extensively in power plants, pulp and paper mills, chemical manufacturing, petro-chemical processing, HVAC and steam distribution systems.

There are many types, manufacturers, body styles, and specialized features, but the they all share some basics operating principles. The video below explains components, operation, and fundamentals.

Classic Controls provides control valve systems for all major industries including chemical, pulp and paper, petro-chemical, power generation, and water treatment.  Classic Control’s experience and engineering background make them a uniquely qualified partner for your next automated valve requirement.

https://www.classiccontrols.com
863-644-3642

Classic Controls Coverage Area and Territory

Classic Controls is a total solutions, single-source provider of industrial process instruments serving Florida, South Georgia, Caribbean North, Caribbean South, Puerto Rico, Trinidad & Tobago, Guyana and Suriname.

Listing by country or island:

Anguilla, Antigua & Barbuda, Aruba, Bahamas, Barbados, Bermuda, Bonaire, British Virgin Islands, Cayman Islands, Curaçao, Dominica, Dominican Republic, Grenada, Guadeloupe, Guyana, Haiti, Jamaica, Martinique, Montserrat, Puerto Rico, Saba, St. Barthélemy, St. Eustatius, St. Kitts & Nevis, St. Lucia, St. Maarten, St. Martin, St. Vincent & the Grenadines, Suriname, Trinidad & Tobago, Turks & Caicos Islands, US Virgin Islands.

Digital Valve Positioner

D3 digital positioner is suitable for linear or rotary valves
Image courtesy of  Flowserve - PMV

A digital positioner is primarily intended for use with modulating control valves. Full featured units will accommodate single or double acting actuators, as well as rotary and linear valves. A digital positioner is a precision instrument and should be treated with a commensurate amount of care to prevent damage during installation and setup.

The positioner will read a control signal input, such as 4-20 mA. The internal processing of the digital positioner will regulate the operation of air supply and venting valves integral to the positioner, regulating the motive pressure on the actuator and the resulting valve trim position. Positional feedback of the valve position is provided by a potentionmeter.

Units can be provided with one of several different communications options to enable setup and diagnostic information to be transmitted across a network. Good air supply quality and pressure will assure the best positioner performance. Various spindle and bracket arrangements are available to facilitate proper mounting of the digital positioner to the valve actuator.

The use of a digital positioner enables superior modulating valve control and repeatability, along with improved diagnostic information. More detail is contained in the document provided below. Share your fluid control challenges with valve automation experts, combining your own process knowledge and experience with their product application expertise to develop effective solutions.

PMV Digital Valve Positioner from Classic Controls, Inc.

Valve Control Monitor Adapts to Wide Range of Actuators

Valve monitor control mounted using cast NAMUR bracket
Courtesy Westlock Controls

Combining control components from various manufacturers can sometimes facilitate the most effective or desirable solution to a process control challenge. This can certainly be true when configuring a control valve installation. Getting the feature set and packaging that best fit the application requirements can yield benefits throughout the useful life of the equipment.

Westlock Controls, manufacturer of valve control monitors, provides a convenient mounting bracket that adapts the installation of their valve control monitors to actuators employing NAMUR mounting patterns. The cast stainless steel bracket is provided in one of three available mounting kits, each complete with all necessary hardware.

More detail about the adapter bracket is found in the datasheet included below. For more information, share your control valve project requirements and challenges with process control valve experts, combining your own process knowledge and experience with their product application expertise to develop effective solutions.

Stainless Steel Cast NAMUR Mounting Bracket from Classic Controls, Inc.

Limit Switches in Valve Actuators

Valve Position Sensor
Courtesy Westlock Controls

Limit switches are devices which respond to the occurrence of a process condition by changing their contact state. In the industrial control field, their applications and product variations are almost countless. Essentially, the purpose of a limit switch is to serve as a trigger, indicating that some design condition has been achieved. The device provides only an indication of the transition from one condition to another, with no additional information. For example, a limit switch triggered by the opening of a window can only deliver an indication that the window is open, not the degree to which it is open. Most often, the device will have an actuator that is positively activated only by the design condition and mechanically linked to a set of electrical contacts. It is uncommon, but not unknown, for limit switches to be electronic. Some are magnetically actuated, though most are electromechanical. This article will focus on limit switch designs and variants used in the control and actuation of industrial process valves.

Valves, devices used for controlling flow, are motion based. The movable portions of valve trim create some degree of obstruction to media flow, providing regulation of the passage of the media through the valve. It is the movement of critical valve trim elements that limit switches are used to indicate or control. The movable valve trim elements commonly connect to a shaft or other linkage extending to the exterior of the valve body. Mounting electric, hydraulic, or pneumatic actuators to the shaft or linkage provides the operator a means to drive the mechanical connection, changing the orientation or position of the valve trim and regulating the media flow. Because of its positive connection to the valve trim, the position of the shaft or linkage is analogous to the trim position and can be used to indicate what is commonly referred to as “valve position”. Limit switches are easily applied to the valve shaft or linkage in a manner that can provide information or direct functional response to certain changes in valve position.

In industrial valve terms, a limit switch is a device containing one or more magnetic or electrical switches, operated by the rotational or linear movement of the valve.

What are basic informational elements that can be relayed to the control system by limit switches? Operators of an industrial process, for reasons of efficiency, safety, or coordination with other process steps, may need answers to the following basic questions about a process control valve:

• Is the valve open? 
• Is the valve closed? 
• Is the valve opening position greater than “X”? 
• Has the valve actuator properly positioned the valve at or beyond a certain position? 
• Has the valve actuator driven the valve mechanism beyond its normal travel limits? 
• Is the actuator functioning or failing? 

Partial or complete answers to these and other questions, in the form of electrical signals relayed by the limit switch, can serve as confirmation that a control system command has been executed. Such a confirmation signal can be used to trigger the start of the next action in a sequence of process steps or any of countless other useful monitoring and control operations.

Applying limit switches to industrial valve applications should include consideration of:

• Information Points – Determine what indications are necessary or useful for the effective control and monitoring of valve operation. What, as an actual or virtual operator, do you want to know about the real time operational status of a valve that is remotely located. Schedule the information points in operational terms, not electrical switch terms. 
• Contacts – Plan and layout a schedule of logical switches that will provide the information the operator needs. You may not need a separate switch for each information point. In some cases, it may be possible to derive needed information by using logical combinations of switches utilized for other discrete functions. 
• Environment – Accommodate the local conditions and hazards where the switch is installed with a properly rated enclosure. 
• Signal – The switch rating for current and voltage must meet or exceed those of the signal being transmitted. 
• Duty Cycle – The cycling frequency must be considered when specifying the type of switch employed. Every switch design has a limited cycle life. Make sure your selection matches the intended operating frequency for the process. 
• Auxiliary Outputs – These are additional contact sets that share the actuation of the primary switch. They are used to transmit additional signals with specifications differing from the primary signal. 
• Other Actuator Accessories – Limit switches are often integrated into an accessory unit with other actuator accessories, most of which are related to valve position. A visual local indication of valve position is a common example. 

Switches and indicators of valve position can usually be provided as part of a complete valve actuation package, provided by the valve manufacturer or a third party. It is recommended that spare contacts be put in place for future use, as incorporating additional contacts as part of the original actuation package incurs comparatively little additional cost.

Employing a properly configured valve automation package, with limit switches delivering valve status or position information to your control system, can yield operational and safety benefits for the life of the unit. Good advice is to consult with a valve automation specialist for effective recommendations on configuring your valve automation accessories to maximize the level of information and control.

When to Use a Globe Valve for Fluid Process Control

Heavy duty industrial globe valve with pneumatic actuator
Masoneilan brand of GE

Industrial process control often involves the regulation of fluid flow. There are almost uncountable types and variants of flow control valves, each with a particular set of attributes that can make it the advantageous choice to meet certain applications.

When the process calls for controlling flow over a range of possible values, known as throttling, a globe valve may be a good candidate for the application.

Globe valves are characterized by the change in direction of fluid flow as it passes through the valve and the plug or disk positioned in an opening through which fluid must pass. The plug is connected to a stem extending to the exterior of the valve body through the bonnet. Movement of the stem will reposition the plug in relation to the opening, providing a successively larger or smaller opening area through which fluid can pass.

Simple globe valve diagram
Courtesy Wikipedia

Globe valves are available in tee, angle, and wye configurations, as well as an enormous range of special configurations to suit specific applications.

What are some potential advantages of globe valves?

• Good throttling and shutoff capability
• Comparatively easy maintenance
• Comparatively short travel of plug from open to closed position
• Seats can usually be resurfaced when worn

What are some limiting factors for globe valves?

• Higher valve pressure drop than some other designs
• No straight through fluid path
• Comparatively higher actuator torque requirements to operate valve

When flow throttling capability is the overriding concern for an application, a globe valve could be a good candidate for consideration. Share your flow control challenges with product specialists. Combining your process knowledge with their product application expertise will produce effective solutions.

Solenoid Valve Operating Principle

One of many solenoid valve variants
Courtesy Burkert

A solenoid is an electric output device that converts electrical energy input to a linear mechanical force.

At the basic level, a solenoid is an electromagnetic coil and a metallic rod or arm. Electrical current flow though the coil produces a magnetic field, the force of which will move the rod. The movable component is usually a part of the operating mechanism of another device. This allows an electrical switch (controller) to regulate mechanical movement in the other device and cause a change in its operation. A common solenoid application is the operation of valves.

A plunger solenoid contains a movable ferrous rod, sometimes called a core, enclosed in a tube sealed to the valve body and extending through the center of the electromagnetic coil. When the solenoid is energized, the core will move to its equilibrium position in the magnetic field. The core is also a functional part of valve operation, with its repositioning causing a designed changed in the valve operating status (open or close). There are countless variants of solenoid operated valves exhibiting particular operating attributes designed for specific types of applications. In essence, though, they all rely on the electromechanical operating principle outlined here.

A solenoid valve is a combination of two functional units.

• The solenoid (electromagnet) described above.
• The valve body containing one or more openings, called ports, for inlet and outlet, and the valve interior operating components.

Flow through an orifice is controlled by the movement of the rod or core. The core is enclosed in a tube sealed to the valve body, providing a leak tight assembly. A controller energizing or de-energizing the coil will cause the valve to change operating state between open and closed, regulating fluid flow.

Share your control valve requirements and challenges with a valve application specialist. Combining your process application knowledge with their product expertise will produce the most effective solutions.