Escolar Documentos
Profissional Documentos
Cultura Documentos
This guide introduces the Cimberio CIM 737, CIM 3737 Commissioning Set – a combined
double regulating valve and separate flow measurement device which provides high accuracy
flow balancing and measurement across all valve settings.
The commissioning sets are suitable for both heating (LPHW) and cooling applications at working
pressures up to 20 bar. Valve sizes between 15-50mm are available as “CR” brass oblique pattern
globe valves; valves from 65mm-1000mm are available as cast / ductile iron butterfly valves.
• a flip up cap housing individual Allen keys for the locking of valve
positions.
• a valve position indicator scale which can be read from any angle.
• an EPDM lined valve plug providing tight shut-off for isolation purposes.
The valves have been tested by BSRIA in water containing high air and dirt levels (see
section 7). The results showed an excellent tolerance to such conditions, providing
confidence that the valves will retain a high level of accuracy and repeatability of flow
measurement under the worst of system conditions.
2
2.1 CIM 727
DOUBLE REGULATING VALVE
REPLACEABLE HANDLE
SMOOTH OPERATION
DZR BRASS
3
2.2 CIM 737
DOUBLE REGULATING SET DN 1/2 - DN 2”
F 52 52 52 52 58 58
CH 28 33 40 51 56 71
A 25 28 31 36 39 45
CH 28 34 40 51 56 71
4
2.3 CIM 3737
DOUBLE REGULATING SET DN 65 - DN 300
120 248
Body union: Fe 360B.
100 212
Gauged diaphragm: stainless steel AISI 316.
°C °F
80 176 Seat rubber: EPDM.
60 140 Disc: stainless steel AISI 316.
40 104 Stem: stainless steel AISI 316.
20
4 6 8 10 12 14 16 18 20 22
68
Bushing: polyamid.
bars
Flanged connections: to UNI 2223 - PN 16.
16 bar at –10 to 100°C – 232 lbf/in2 at 14 to 212°F
16 bar at –10 to 120°C – 287 lbf/in2 at 14 to 248°F
PN 16 16 16 16 16 16 16 16
N. holes 4 8 8 8 8 12 12 12
5
THE NEED FOR HIGH ACCURACY FLOW
3 BALANCING AND MEASUREMENT
FACILITATE TROUBLE-SHOOTING:
In the event of poor system performance, the presence of
balancing valves and flow measurement devices will
enable engineers to establish the locations and causes of
flow problems.
6
ADVANTAGES OF FIXED ORIFICE OVER
4 VARIABLE ORIFICE FLOW MEASUREMENT
The idea to couple a double regulating valve to a fixed orifice device evolved in the UK in the
1980s. This combination was designed specifically to overcome the accuracy problems
associated with flow measurements utilising the pressure drops across variable orifice valves.
Variable orifice valves seldom
achieve the accuracy and
reliability of fixed orifice valves.
For a variable orifice valve, the
pressure signal across the plug is
used for flow measurement. A
graph of the relationship
between pressure drop and flow
rate is required for each valve
setting.
The fundamental weakness of
this design is that manufacturing
CIM 721 CIM 721 PRESSURE
tolerances can cause significant FIXED ORIFICE SIMULATION
flow measurement distortions
beyond a certain closure point, typically 50% closed. Beyond this point the flow measurement
accuracy can deteriorate dramatically, to ±30% or more! Since most of the valve’s resistance is
added in the last part of its closure, the valve’s balancing range is severely limited. The result
is a valve, which has either limited balancing capability, poor flow measurement accuracy, or
both. The limited operating range of variable orifice valves inevitably makes valve selection
more difficult, often resulting in valve sizes which are lower than adjoining pipe sizes.
Fixed orifice valves have none of these problems. Because the flow measurement function is
separated from the balancing function they can be regulated to nearly closed positions,
achieving much higher balancing pressures whilst maintaining flow measurement accuracy
within ±5% at any setting.
Since their introduction, fixed orifice commissioning sets have become by far the
most preferred choice for UK design engineers and installation contractors.
7
5 DESIGN ADVANTAGES OF FIXED ORIFICE VALVES
To avoid the requirement for high balancing pressures, a popular approach amongst design
engineers has been to design systems such that some degree of self-balancing is achieved due
to the sizing and arrangement of pipe circuits. Typical design solutions might include the use
of reverse return circuits, low pressure loss distribution mains or the selection of terminal units
with equal resistances.
While this approach can help to achieve well balanced system flow rates, care must be taken
to avoid the following disadvantages:
• Low pressure loss mains are effectively over-sized pipes which are more
expensive than necessary and provide low velocity collecting points where
air can accumulate and corrosion can take place.
• Selecting terminal units with equal resistances effectively means that many
locations will end up with over-sized terminal units which will cost more and
exhibit poor control.
In addition to these points, by designing for self-balancing, the designer usually has
to spend more time on the design to ensure that pressure variations are as small as
possible, and that any remaining imbalance can be dealt with by the limited
trimming ability of a less accurate balancing valve.
8
6 FLOW AND PRESSURE SIMULATION GRAPHS
Computational fluid dynamics software has been used to demonstrate the stable pressure and flow
patterns across Cimberio balancing valves at different settings. The analysis shows that,
due to the compact body of the valve, turbulent zones and eddy currents are minimised, thereby
ensuring stable performance and resistance to air and dirt related problems.
CIM 727 Flow simulation graphs
9
7.1 BSRIA VALVE TESTING REPORT
BSRIA is the UK’s leading centre for building services research. BSRIA offer independent and
authoritative research, information, testing and consultancy and market intelligence.
(e-mail: bsria@bsria.co.uk web: www.bsria.co.uk)
Since trapped air and dirt are the main causes of non-repeatable flow measurements
in small sized valves, we commissioned BSRIA to investigate their impact on the
performance of Cimberio balancing valves.
OBJECTIVES
• Determine the effects of trapped air on the kv values of each of the valves
at the 25% open setting
RESULTS
The graph below shows the results of the effects of trapped air on each of the three
valves when set at their 25% open positions.
10
7.2 BSRIA VALVE TESTING REPORT
The graph below shows the results of the effects of dirty water on each of the three
valves when set at their 25% open positions.
BSRIA’S CONCLUSIONS
“The results show that the valves tested are not significantly affected by the
presence of trapped air or fine dirt material suspended in the fluid stream.
For each test, the valve resistance was found to vary by less then 10% which is
extremely unlikely to produce a measureable variation in water flow rate.
Furthermore, the results show that by closing and re-opening the valve to its
locked position the resistance across the valve is repeatable within acceptable
limits.”
11
LOCATING REGULATING VALVES
8 AND FLOW MEASUREMENT DEVICES
Isolating valve Double Regulating Valve Orifice type flow measurement device
Double regulating valve close coupled to flow measurement device Motorised three way valve Non-return valve
The convention in heating systems is to position regulating valves on the return sides of pipe
circuits where the water is coolest. In this position, valve pressures are more likely to be above
the water vapour pressure (and cavitation region), since vapour pressure increases with
temperature. In chilled water circuits the valve location makes little difference, although the
same convention tends to be applied.
Orifice type flow measurement devices usually require a uniform pattern of flow
through them to ensure measurement accuracy. Therefore, it is recommended
that at least 5 diameters of straight pipe are allowed upstream of each device.
12
9 LOW FLOW COMMISSIONING SETS
The smallest valve size in the range is 15mm nominal diameter. Because many modern systems
incorporate low duty terminal units with low flow requirements (typically down to 0.02 l/s),
the 15mm commissioning sets have to be able to accommodate an unusually large range of
flow rates. For this reason, four alternative valve/flow measurement device combinations
are available. Flow measurement devices are available as standard, medium
or low flow types. Double regulating valves are available as standard and low flow.
The combinations in which the Cim 737 15mm can be close coupled are shown below.
+ + + +
= = = =
It can be seen from the Valve Selection Table (Page 15), that the low flow valves and flow
measurement devices have high values. This is because, at such low flow rates, a high
resistance is required to generate a measureable pressure differential. In practice, because
the flow rates are so small, the pressure drops across these devices are not excessive
(typically 3kPa maximum).
13
10.1 GUIDE TO VALVE SELECTION
Calculate circuit
residual pressures.
14
10.2 GUIDE TO VALVE SELECTION
DRV Double Regulating Valve FMD Flow Measurement Device Q Flow rate (l/s)
* Flow rates required to generate a minimum 1 kPa loss signal across the FMD.
15
10.3 GUIDE TO VALVE SELECTION
100
80
CIM 727 60
50
40
30
20
Pressure Loss – ∆P [kPa]
10
8
6
OW
5
”
FL
1/2
4
”
3/4
/4
OW
/2
2”
1”
1”1
1”1
3 ”L
1/2
1
0.8
0.6
0.5
0.4
0.3
0.2
0.1
0.004 0.006 0.008 0.01 0.02 0.04 0.06 0.08 0.1 0.2 0.3 0.4 0.6 0.8 1 2 3 4 6 8 10 20
20
0
0
65
80
10
12
15
20
25
30
DN
DN
DN
DN
DN
DN
DN
DN
Pressure Loss – ∆P [kPa]
10
8
6
5
4
3
1
0.8
0.6
0.5
0.4
0.3
0.2
0.1
0.4 0.6 0.8 1 2 4 6 8 10 20 30 40 60 80 100 200 300 400 600 800 1000 2000
16
10.4 GUIDE TO VALVE SELECTION
100
80
CIM 721 60
50
40
30
20
Pressure Loss Signal – ∆P [kPa]
10
8
628
000
76
99
73
57
351
52
0.9
1.7
6 0.4
16.
23.
4.0
7.4
47.
s=
s=
s=
5
s=
s=
s=
s=
s=
Kv
Kv
Kv
Kv
Kv
Kv
Kv
Kv
2”
3
”
”
4”
1/4
1/2
1/2
1/2
–1”
1/
–2”
–3/
–1”
–1”
M–
S–
L–
721
2
721
721
721
721
721
721
721
1
0.8
0.6
0.5
0.4
0.3
kvs P
0.2
Q=
36
0.1
0.004 0.006 0.008 0.01 0.02 0.04 0.06 0.08 0.1 0.2 0.3 0.4 0.6 0.8 1 2 3 4 6 8 10 20
20
Pressure Loss Signal – ∆P [kPa]
10
0
0
.00
.00
.00
.00
.00
8.0
7.0
8
70
234
358
512
911
88.
136
143
205
6
s=
s=
s=
s=
s=
s=
s=
s=
5
Kv
Kv
Kv
Kv
Kv
Kv
Kv
Kv
4
5
00
25
50
00
3
0
50
00
N6
N8
N1
N1
N1
N2
N2
N3
1–D
1–D
1–D
1–D
1–D
1–D
1–D
1–D
2
372
372
372
372
372
372
372
372
1
0.8
0.6
0.5
0.4
0.3
kvs P
0.2 Q=
36
0.1
0.4 0.6 0.8 1 2 4 6 8 10 20 30 40 60 80 100 200 300 400 600 800 1000 2000
17
11.1 PROPORTIONAL BALANCING OF FLOW RATES
PROCEDURE
1. Ensure that the total flow rate entering the branch is between 110% - 120% of the
design flow rate. It may be necessary to close down other branches to achieve this.
2. Measure the flow rates through each sub-branch. For each sub-branch calculate the
% design flow rate:
Pmeasured
% design flow rate =
Pdesign
If the signals at any of the installed flow measurement devices are below the
measurement range of the device, further increase the flow rate entering the branch by
closing down adjacent branches.
3. Identify the index sub-branch. This will be the one with the lowest % design flow
rate. Usually, but not always, this will be the end sub-branch (furthest from the
pump) e.g. Terminal 5 in the above schematic.
If the end sub-branch is not the index, then close its regulating valve until its
% design flow rate is approximately 10% less than that at the true index
(so that the end sub-branch becomes an artificial index). This needs to be done
whilst simultaneously measuring the flow at the true index, since its flow rate will
change as the end branch is adjusted. Hence, two operatives each with
manometers and 2-way radios will speed this exercise.
18
11.2 PROPORTIONAL BALANCING OF FLOW RATES
5. Having achieved equal % design flow rates for each of the sub-branches, the sub-
circuit flow rates are now balanced. This balance cannot be disturbed by the
adjustment of upstream valves. Hence, upstream branches can be balanced in exactly
the same way.
6. Once the entire system has been balanced, adjust the flow from the pump to 110%
of the total design flow rate for the system. All branches and sub-branches should
now have flow rates close to their 100% design values.
For a more detailed description of the balancing procedure complete with a worked example,
reference should be made to the Cimberio Commissioning Guide.
• Where the end sub-branch is a long way from the main branch valve, (outside the
range of a remote indicating manometer) three persons with radios would be
required for balancing.
19
12 MEASURING EQUIPMENT
By measuring the pressure differential across a fixed resistance (such as an orifice plate)
the flow rate through a pipe can be determined utilising the square law relationship
between pressure differential and flow rate. Experience has shown that this method of
determining flow rate is the most convenient for use in the building services industry.
FLUOROCARBON MANOMETER
DIGITAL MANOMETER
20
13.1 TERMINOLOGY
Double regulating valves (DRVs) are so called because they serve the double function of flow
regulation and isolation. Once set in their regulated position, they can be locked so that when
closed and re-opened, they cannot be opened beyond their set position.
Flow measurement devices enable flow rate to be measured for the purposes of achieving and
proving a flow balance. Fixed orifices provide a highly accurate means of flow
measurement in pipe systems. By measuring the pressure differential across an orifice,
this can be equated to flow rate using the manufacturer’s published kvs value.
This term simply refers to the close coupling of regulating valves to orifice type flow
measurement devices. The orifice is screwed into the inlet side of the regulating valve.
INDEX CIRCUIT
This is the circuit which, with the system in an unbalanced state, exhibits the greatest
resistance to flow. It can be identified by calculation as the circuit with the highest pressure
loss around it when design flow rates are assumed. On site it can be identified by flow
measurement; it will be the circuit for which the ratio of measured flow rate to design flow
rate is lowest.
All systems will have a single overall index circuit against which pump pressure is calculated.
Furthermore, for any branch serving sub-branches, there will be an index sub-branch.
Similarly, each sub-branch may serve a number of terminal branches, one of which will be the
index terminal.
If all terminal branches are of equal resistance, the main system index circuit is likely to be
from the pump to the most remote terminal, since this circuit has the longest pipe lengths.
Similarly, sub-branch index circuits are likely to be from the start of the sub-branch to the most
remote terminal unit they serve. However, if terminal branch resistances vary then
the system index and branch indexes will not necessarily coincide with the most remote
terminals. The location of each index will then depend on which circuit has the highest
combination of pipe and terminal branch pressure losses.
As the circuit starting with the highest resistance, there is no need to regulate flow at an
index. At the end of the balancing process, the index circuit should always have a fully open
regulating valve.
21
13.2 TERMINOLOGY
RESIDUAL PRESSURE
The residual pressure for a particular circuit is the difference between the pressure available
across that circuit, and the pressure required to achieve the design flow rate. This residual, or
excess pressure, has to be dissipated in some way, and this is usually achieved by adding
resistance to the circuit in the form of a regulating valve.
A circuit’s residual pressure is, therefore, critical for sizing regulating valves. A valve’s
resistance obviously increases as it is closed, but there is a limit to how much resistance it can
generate. As a rule of thumb, if a valve is closed beyond its 25% open position it may become
sensitive to air bubbles or prone to blockage from circulating debris.
Valve selection must therefore include a check to ensure that predicted residual pressures are
within the operating limits of the selected regulating valve. Fortunately, many pipe sizing
programs calculate residual pressures automatically. These values can then be checked against
the operating range of the selected valve.
22
13.3 TERMINOLOGY
KV
The kv value represents the flow rate through a fully open valve at a temperature
between 5degC and 40degC, and measured in cubic metres per hour that will induce a
pressure loss of 1bar. Hence the kv value is effectively a measure of the valve’s resistance.
Where a valve is close coupled to a flow measurement device, the kv value represents the
resistance across the fully open valve and flow measurement device combined.
Using SI units, the pressure drop across a fully open valve can be calculated from the
equation:
2
Q
p = 1.296 x 10 6 – where Q = flow rate in l/s, and p = pressure loss in Pa
kv
kv values express resistance as an inverse - in other words the greater the valve’s
resistance the smaller its kv value. Design engineers are more used to thinking of
resistance in terms of the pressure loss coefficient (zeta) sometimes also referred to
as a "k factor". The pressure loss through any fitting or component can be calculated
from the equation:
v2
p = –––
2
where = fluid density in kg/m3, v = velocity in m/s and p = pressure loss in Pa.
The higher the loss coefficient, the greater the resistance of the fitting.
For convenience, the valve selection charts in this guide express fully open valve
resistances in terms of both kv values and pressure loss coefficients
KVS
This term is usually applied to the pressure loss between the tappings on a flow
measurement device. The "s" indicates "signal" since it relates to the pressure loss signal
measured by a commissioning specialist. For a given flow measurement device with a
known kvs value the commissioning specialist can calculate flow rate from the pressure
loss signal using the following equation:
kvs P
Q= where Q = flow rate in l/s, and P = pressure loss in kPa
36
However, the pressure loss between the tappings is not the same as the overall
pressure loss across the device. Because there is an increase in static pressure
downstream of the orifice, the overall pressure loss is usually less than the measured
pressure loss across the tappings. To determine the pressure loss across one of
our flow measurement devices, use the pressure loss coefficient (zeta) from the
Valve Selection Table (Page 13).
23
28017 SAN MAURIZIO D'OPAGLIO (Novara) - Italy
Via Torchio, 57
Tel. +39 0322 923001 - Fax +39 0322 967216 / 967755
www.cimberio.com - e.mail: info@cimberio.it