UNIVERSIT DEGLI STUDI DI SALERNO

FACOLT DI INGEGNERIA
Bachelor Degree in Chemical Engineering
Course:
Instrumentation and Control of Chemical Processes
CONTROL VALVE SIZING
CONTROL VALVE SIZING
Rev. 3.51 June 13, 2012
THE CONTROL VALVE SIZING PROBLEM
Calculations or choices to do:
Capacity (based on the concept of C
V
introduced in the
40s)
DN
Inherent characteristic
Valve type (globe, butterfly, modulating ball, etc.)
Construction material (depending upon temperature,
pressure, corrosive and erosive properties of the fluid)
Body shape, plug and bonnet
Type and size of the actuator, servo-positioning device
Safety items (e.g., action type in case of failure),
reliability, maintenance
noise evaluation
15.06.2012 2 Instrumentation and Control of Chemical Processes - Prof. M. Miccio
KNOWN DATA:
NPS (NOMINAL PIPE SIZE) OF THE PIPING
FLUID (LIQUID IN OUR CASE)
INLET TEMPERATURE T
1
P = (P
1
- P
2
)
FLOW
mass flow rate, volume flow rate
design at nominal / max / min flow rate
MANUFACTURER TABLE
1. TO BE CHOSEN:
VALVE TYPE (GLOBE / BALL / BUTTERFLY)
TYPE OF INHERENT CHARACTERISTIC
CONSTRUCTION MATERIAL
2. TO BE DETERMINED:
NPS
C
vn
3. TO BE CHECKED:
CAVITATION (calculation of P
c
or P
MAX
)
CONTROL VALVE SIZING
Design case
Taking suitable data
from the
MANUFACTURER TABLE
15.06.2012 3 Instrumentation and Control of Chemical Processes - Prof. M. Miccio
MANUFACTURER TABLE
An example for an angle globe valve
C
vn
C
vn
15.06.2012 4 Instrumentation and Control of Chemical Processes - Prof. M. Miccio
When F
L
is not present in MANUFACTURER TABLE:
AnnexD_ISA_7501-1985
VALVE SIZING PROBLEM
2 different design cases
1. the valve is a stand-alone unit
2. the valve is inserted in an equipment process scheme
15.06.2012 5 Instrumentation and Control of Chemical Processes - Prof. M. Miccio
6 Instrumentation and Control of Chemical Processes - Prof. M. Miccio 15.06.2012
Flow coefficient
calculation:
Once known NPS and Cv, a valve has to be chosen
from the manufacturer table such as:
Check cavitation according to IEC 60534 norm
NORMAL FLOW
CHOKED FLOW
according to
IEC 60534 norm
A valve has to be chosen with a NPS one size
lower than piping diameter (if possible)
DATA: liquid substance, , Pc, Tc, G
f
, F
F,
P
v
Operating Conditions: P
1,
P
2,
T
1
, flow rate
Piping: DN
Valve: K
c
, F
L
, manufacturer tables,
intrinsic characteristic.
END OF SIZING
) P F P ( F P
V F 1
2
L MAX
=
A higher F
L
valve has to be
choosen (low
pressure
recovery valves)
(possibly)
SIMPLIFIED SIZING
PROCEDURE
according to
Magnani, Ferretti e
Rocco (2007)
max 2 1
P ) P P ( P < =
c 2 1
P ) P P ( P =
f 2 1 v
G ) P P ( V C =

False
True
False
True
v 7 . 0 h v v
C C C =
=

70%rule
CONTROL VALVE SIZING
Design case
The simplified procedure presented in the flow chart is valid for globe valves.
In fact the rotary valves are not characterized by the travel h, but by the
opening angle .
For rotary valves, the simplified sizing procedure is referred to an angle *,
which corresponds the 70% max opening angle (90):
Strictly
In practice
Remarks
A rotary valve usually has one and only one inherent characteristic.
Butterfly valves have often an inherent characteristic with an inflection point
(such as V-port).
Modulating ball valves have often an equal percentage inherent
characteristic.
* = (70/100) 90 = 63
* = 65 or 70
Rotary Valves
15.06.2012 7 Instrumentation and Control of Chemical Processes - Prof. M. Miccio
CONTROL VALVE SIZING
Design case
The MANUFACTURER TABLE: several cases are possible
a) For each NPS, the MANUFACTURER TABLE reports C
vn
as well as C
v
values for different values of h ()
Inherent characteristic already known for points
b) The MANUFACTURER TABLE only shows the value of C
vn
for each NPS,
furthermore the manufacturer gives a diagram of or C
v
as a function of h ().
For the inherent characteristic use the manufacturers diagram
c) The MANUFACTURER TABLE only shows the C
vn
value for each NPS
Use formulas for the inherent characteristic
15.06.2012 8 Instrumentation and Control of Chemical Processes - Prof. M. Miccio
INTERACTIVE EXERCISES on the WEB
Initial exercises and reference examples/problems are interactively available
on the WEB.
NOTE:
They work by means of Mathcad Calculation Server without the Mathcad
software installed on your own PC.
15.06.2012 9 Instrumentation and Control of Chemical Processes - Prof. M. Miccio
http://asp.diin.unisa.it
http://asp.diin.unisa.it/MCS/miccio/WEB_diagramma_PHI_EN.xmcd
KNOWN DATA:
VALVE TYPE
NPS (NOMINAL PIPE SIZE) OF THE VALVE
NOMINAL FLOW COEFFICIENT C
vn
INHERENT CHARACTERISTIC
FLUID (LIQUID IN OUR CASE)
TEMPERATURE T
1
P = (P
1
- P
2
)
1. TO BE DETERMINED:
NOMINAL FLOW RATE (h = 1 OR = 90)
FLOW RATE at a given value of h OR
2. TO BE CHECKED:
CAVITATION (calcolo di P
c
or P
MAX
)
CONTROL VALVE SIZING PROBLEM
Verify case
15.06.2012 10 Instrumentation and Control of Chemical Processes - Prof. M. Miccio
DEFINITIONS:
INSTALLED CHARACTERISTIC:
It is the relationship between the flow rate and the (linear
or rotary) valve opening when the valve is inserted in the
circuit and influenced by process condition.
PRESSURE DROP across the valve:
NOMINAL (or RATED) PRESSURE DROP:
VALVE AUTHORITY:
It is the ratio between the nominal pressure drop (P
n
)
across the valve and the total pressure drop of the
circuit (P
0
).
1 =
=
h v n
P P
0
n
P
P
V

=
INSTALLED CHARACTERISTIC
The installed characteristic will be an implicit function:
( ) kg/s ] [ ) h ( w P G ) h ( C N ) h ( w ) h ( m
v f v 1
= = = &
P
3
15.06.2012 11 Instrumentation and Control of Chemical Processes - Prof. M. Miccio
v
P
The circuit is formed by a control valve and an user in which all the pressure drop is concentrated.
A pump supplies the pressure P
M
P
S
, assumed constant.
We can evaluate the role of the pressure drop across the valve comparing it with the total pressure drop
of the circuit:
I. it should be high in order to improve the control of the flowrate;
II. on the other hand. It should be low in order to reduce costs of pump energy.
The aim is to find a good technical compromise solution between these two opposing evidences.
P
v
= P
1
- P
2
P
0
= P
u
+ P
v
HYPOTHESES:
P
0
= P
M
- P
S
= constant
Negligible pressure drop along the pipe:
a) P
M
= P
1
b) P
S
= P
3
User pressure drop as a square function of the
velocity and therefore, for incompressible fluid, is a
square function of the mass flowrate :
No accumulation in the circuit
P
3
P
u
= P
2
(w(h)) P
3
= w
2
(h)
INSTALLED CHARACTERISTIC
15.06.2012 12 Instrumentation and Control of Chemical Processes - Prof. M. Miccio
travel nominal travel
h 1
(h) 1
C
v
(h)=(h) C
vn
C
vn
P
2
= P
3
+ w
n
2
P
v
(w(h)) = P
1
- P
2
(w(h)) = P
M
- P
S
- w
2
(h)= P
0
w
2
(h)
P
n
= P
0
w
n
2
With these hypotheses, the installed characteristic equation can be evaluated assuming V as
parameter.
It is important to evidence the trend of the installed characteristic when changing V for a valve having
linear or equal percentage inherent characteristic.
( ) ( ) )) h ( w ( P G h C N h w
f vn 1
=
n f vn 1 n
P G C N w =
( ) ( ) h w P ) h ( w P
2
3 2
+ =
INSTALLED CHARACTERISTIC
15.06.2012 13 Instrumentation and Control of Chemical Processes - Prof. M. Miccio
u 0 v
P P P =
3 2 u
P P P =
3 1 0
P P P = For: where and
2
n 0 n
w P P =
( ) [ ] ( ) [ ] ( ) [ ] ( ) [ ]
2
0
2
3 1 2 1 v
h w P h w P P h w P P h w P = = =
n
2
n 0
w
P P
=
Replacing in previous equation, we have:
( )
(

|
|

\
|
=
n
2
n
2
n 0
0 f vn 1
w
w
P P
P G ) h ( C N h w
( ) ( ) [ ] ( )
(

|
|

\
|
= h w
w
P P
P G h C N h w
2
n
2
n 0
0 f
2
vn
2
1
2 2

( )
( ) [ ]
( ) [ ]
|
|

\
|
+

=
n
2
n 0
f
2
vn
2
1
2
0 f
2
vn
2
1 2
w
P P
G h C N 1
P G h C N
h w

INSTALLED CHARACTERISTIC
15.06.2012 14 Instrumentation and Control of Chemical Processes - Prof. M. Miccio
see ch.5 in Magnani, Ferretti e Rocco (2007)
Multiplying and dividing numerator and denominator for
n
n
P
P

we obtain:
( )
( ) [ ]
( ) [ ] ( ) [ ]
n
n
n
2
n f
2
vn
2
1
2
0 f
2
vn
2 2
1
n
2
n
n
0 f
2
vn
2 2
1
P
P
w
P G h C N P G h C N w
P
P
P G h C N
h w

n f vn 1 n
P G C N w =
n f
vn
2
1
2
n
2
P G C N w =
replacing:
( )
( ) [ ]
( ) [ ] ( ) [ ]
2 2
n
n
0
2 2
n
2
n
n
0
2
n
2
n
h w
P
P
h w w
P
P
h w
w h w

=
INSTALLED CHARACTERISTIC
15.06.2012 15 Instrumentation and Control of Chemical Processes - Prof. M. Miccio
( )
( ) [ ]
( ) [ ] ( ) [ ]
2 2
2
1
1
1
h
V
h
V
h
w
h w
n

=
Dividing for [(h)]
2
and multiplying for V in the square root, we have a non-dimensional final eq.:
( ) ( )
( ) [ ]
2
n n
h
V
V 1
1
V
h V
w
h w

+
= =
&
&
After using the AUTORITHY definition :
0
n
P
P
V

=
The installed characteristic equation simplifies for the particular cases:
V = 1
(h) = 1
INSTALLED CHARACTERISTIC
15.06.2012 16 Instrumentation and Control of Chemical Processes - Prof. M. Miccio
see ch.5 in Magnani, Ferretti e Rocco (2007)
VALVE SIZING PROBLEM
2 different design cases
1. the valve is a stand-alone unit
2. the valve is inserted in an equipment process
scheme
15.06.2012 17 Instrumentation and Control of Chemical Processes - Prof. M. Miccio
P
3
Selection criterion of inherent characteristic
If V is known a priori, the selection is based on the value of V:
if V > 0.4, the linear inherent characteristic is chosen
if V 0.25, the equal percentage inherent characteristic is chosen
if 0.25 < V 0.4, the parabolic or equal percentage or modified linear
inherent characteristic is chosen
If V is unknown, a parabolic or modified inherent characteristic is chosen
Linear inherent characteristic
Equal percentage
inherent characteristic
NOVEL SELECTION CRITERION
OF THE CONTROL VALVE
The selection of the inherent characteristic is based on the process requirements of the installed characteristic
C
vn
is always chosen after the C
v
*
calculation based on the 70% rule
installed characteristic
closer to linearity
15.06.2012 18 Instrumentation and Control of Chemical Processes - Prof. M. Miccio
FLOW FACTOR K
v
It is not commonly used.
It defines the volume flow rate of water in m
3
/h at 15C (5-40C) which flows across the
valve for a known closure member travel producing a pressure drop equal to 1 bar.
0
v
v
P
) K ( P
V K

=
&
[=] m
3
(H
2
O)/(h(bar)
1/2
)
where:
= volume flow rate
P(K
v
) = reference pressure drop (usually 1 bar)
P = actual pressure drop

0
= density of water
= actual density of the fluid
C
v
= 1.16 K
v
K
v
= 0.865C
v
V
&
15.06.2012 19 Instrumentation and Control of Chemical Processes - Prof. M. Miccio
CONTROL VALVE SIZING:
other cases/problems
LIQUID IN LAMINAR REGIME
COMPRESSIBLE FLUIDS (GAS AND VAPORS)
TWO-PHASE MIXTURES (LIQUID-GAS MIXTURES)
PIPE SIZE REDUCTION
NOISE EVALUATION
15.06.2012 20 Instrumentation and Control of Chemical Processes - Prof. M. Miccio