Allowable vapor control valve pressure drops | Hydrocarbon Processing | March 2008 1

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COPYING AND DISTRIBUTING ARE PROHIBITED WITHOUT PERMISSION OF THE PUBLISHER

Allowable vapor control valve pressure drops

03.05.2008

| Yu, F., Jacobs Engineering Group, Houston, Texas

Understand the relationship between the pressure drop and the process system
Keywords:
In a previous article, the author stated the advantage of sizing control valves using the minimum allowable control
valve pressure drop at maximum flow over other methods.1 In this article, more information is provided about the
relationship between the allowable control valve pressure drop and the process system it serves. Only vapor control
valve allowable pressure drop is discussed.
From an engineering design viewpoint, we want to select a control valve that is able to regulate the process fluid
over a desired flow range, a smaller valve control valve to reduce capital cost and less control valve pressure drop
to reduce operating cost.
The control valve is part of a process system. Its function is to regulate process flow so that certain process
conditions can be maintained. A process system consists of source and destination equipment, with a process line
to move process fluid from the source to the destination. In the process line, there are other process equipment,
instruments, valves and fittings to process the process fluid. Process variables in a process system are inlet/outlet
temperatures and pressures, flowrate, line size, and control valve and system pressure drops. In this article, system
pressure drop is defined as the total pressure drop of process equipment, instruments and line excluding the
control valve pressure drop in a process system. The static head difference in a vapor system is small and can be
ignored. Increase the flowrate and the available pressure drop for a control valve and system will be reduced and
vice versa.
If the process system has a compressor, it will be the source equipment. Usually it is a centrifugal compressor, and
the system pressure will be affected by its performance curve. A centrifugal compressor will generate lower head or
lower system inlet pressure at high flow, and higher head or higher system inlet pressure at low flow.
In most cases, the process engineer will supply the allowable vapor control valve pressure drop for the instrument
engineer to size and select the control valve. Process engineers sometimes specify the allowable control valve
pressure drop at maximum, normal and minimum process flowrates, but sometimes only provide it at normal
flowrate (since it is readily available from a hydraulic calculation).
Basis. The most common control valves used in industry are globe and rotary (butterfly or ball). A globe control
valve is usually smaller than a rotary control valve. The division between these two types of control valves is 6 in. to
8 in. The strategy of selecting a ball or butterfly rotary control valve is to select the ball type first since it has a
wider operating range. Then, select the butterfly rotary control valve for higher flow applications.
The acceptable operating range of each control valve type varies among the professionals. In general, the
acceptable operating range for a globe control valve is 20% to 90% open. The acceptable operating range for a ball
rotary control valve is 15 to 90 open. The acceptable operating range for a butterfly rotary control valve is 15 to
60 open.
In this article, it is assumed that the acceptable globe control valve operating range is 20% to 90% open, and the
acceptable rotary control valve operating range is 20 to 90 open. Furthermore, it is assumed that the piping

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geometry factor is ignored.

Basic equations. Each process system is designed to handle process fluid over a maximum to minimum flow
range, with normal flow between these two extremes. The process engineer's job is to carry out a hydraulic
calculation for the process system based on normal flow to find out its pressure profile and allowable control valve
pressure drop. Besides the system hydraulic calculation, another source of allowable control valve pressure drop is
from the compressor hydraulic calculation, which is usually based on rated flow.
Control valve size usually depends on the maximum flow and the allowable control valve pressure drop. A smaller
allowable control valve pressure will result in a larger control valve. In most cases, it is justified to have a larger
control valve with a smaller pressure drop, since the higher control valve cost can be recovered by the reduced
operating cost.2 If we assign a small allowable vapor control valve pressure drop, DPo?, at maximum process flow
rate, Qo?, allowable control valve pressure drop at normal and minimum flow can be calculated as:

where DPso is system pressure drop at maximum flow and DPx is control valve pressure drop at normal flow, (Q?1,
x = 1), or minimum flow, (Q?2, x = 2). The system pressure drop in this study is the sum of all the line, equipment
and instrument pressure drops that vary with flow. DPh is the compressor head or pressure increase at normal or
minimum flow over the maximum flow. Eq. 1 is a general equation, applicable to any process system.
Since in most cases, system pressure drop at normal flow, DPs1, is calculated, system pressure drop at maximum
flow, DPso?, can be estimated by the following equation:

For a vapor control valve, control valve C?Vo at maximum process flow or C?Vx at another flow can be calculated
by the following equations:

where P1 is control valve inlet pressure in psia, T1 is control valve inlet temperature in R (Rankine), Gg is the ratio
of gas molecular weight to air and Z is the gas compressibility factor. CVo and CVx are control valve CV at
maximum and other flowrates, Q x in scfh.
Xx is the ratio of control valve pressure drop (DPx?, x = 0,1,2) to P1, dimensionless. It is calculated by the following
equation:

Yx is the expansion factor (ratio of flow coefficient for a gas to that for a liquid at the same Reynolds number),
dimensionless. It is calculated by the following equation:

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Fk is the ratio of specific heat ratio of gas, k, to that of air, 1.4. XTx is the pressure drop ratio factor for a control
valve without attached fittings. It is the pressure drop ratio required to provide critical or sonic flow through the
valve when Fk = 1.0. Yx is larger than 0.667 when flow through the control valve is subsonic, and it is 0.667 when
flow through the control valve is sonic. XTx varies with control valve opening and its value is given in the valve
manufacturer's catalog.
By taking a ratio of Eqs. 3a and 3b, the following equation can be obtained:

From Eqs. 1 and 4, following equation can be obtained in terms of Q x/Q o:

Qo , DPo , DPso , Yo and CVo (at maximum flowrate) are known since they are used to select a control valve. Once a
control valve is selected, its CVx at any other control valve opening can be found from a control valve catalog. Flow
at this control valve opening, Qx , can be calculated by iteration using Eqs. 5, 3c, 3d and 1.
Applications. The previous equations are used to study the relationship of allowable vapor control valve pressure
drop and its process system. To simplify the analysis, air at 60F will be used as the process fluid. Air pressure at
the control valve inlet is 100 psig. Line size is chosen so that line pressure drop is about 1 psi/100 ft at maximum
flowrate.
The process flow operating range is selected to be from 50% (minimum) to 110% (maximum) of normal flow. The
allowable vapor control valve pressure drop is assigned based on maximum flow rate, Qo. For each flow case, a
control valve is selected using the manufacturer's control valve catalog.
Results of the study for globe control and rotary control valves are:
A. For a globe control valve, maximum air flowrates of 600, 3,000, 150,000, 420,000 and 840,000 scfh are
selected, using 1 in., 2 in., 4 in., 6 in. and 8in. lines respectively. Five system pressure drops (based on maximum
flow) are selected: 5, 25, 50, 75 and 100 psi for each flow case.
The following factors are studied:
1. Allowable vapor control valve pressure drop, DPo, at maximum flow, Qo:
Allowable vapor control valve pressure drops of 5, 10 and 15 psi are selected. The control valve is selected close to
the maximum acceptable valve opening (90% open) with an equal-percentage characteristic. Table 1 shows the
results.

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From Table 1, we see that, in general, a larger globe control valve is required if the allowable control valve pressure
drop is smaller. But sometimes the same control valve is selected for different allowable control valve pressure
drops (see the maximum flow = 3,000 scfh).
2. Control valve performance at different system pressure drops, DPso:
This study is based on a control valve selected using an allowable control valve pressure drop of 5 psi at maximum
air flow (Table 1). At acceptable minimum and maximum control valve openings (20% and 90%), flow through the
control valve in terms of percentage of normal flow is calculated for various system pressure drops (at maximum
flow). Results are listed in Table 2 for maximum air flows of 3,000, 150,000, 420,000 and 840,000 scfh. Our
target is that the control valve is able to operate over 50 to 110% of normal flow.

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From this table we see that the selected globe control valves are able to operate over a 50% to 110% flow range,
operating flow range is 103% to 108% of normal flow for a system pressure drop of 5 psi and 95% to 79% of normal
flow for a system pressure drop of 25 to 100 psi. The operating flow range reduces as the system pressure is
increased. For the 100 psi system pressure drop cases, flow at 20% control valve opening is sonic, since Y2 = 0.667,
3. Select control valve away from the acceptable maximum control valve opening:
Table 2 control valves are selected close to the acceptable maximum opening (90% open). Control valve
performance selected away from the maximum opening is listed in Table 3.

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Comparing the globe control valve performance to the corresponding one in Table 2, it can be seen that a larger
control valve is selected if valve selection is away from the maximum acceptable opening (higher capital cost).
Comparing the operating ranges of Table 3 control valves to those in Table 2, Table 3 control valves are not able to
operate at the minimum flow (50% of normal flow) for a system with a larger system pressure drop (25 or 50 to
100 psi) since at 50% of normal flow, control valve opening will be less than the acceptable lower limit, 20% open.
Separate calculations for 150,000 scfh and 420,000 scfh show that if the control valve is selected at 66% and 73%
opening, selected control valves (4 in., cv = 224; 8 in., cv =567) are still able to operate over the whole flow range.
Table 3 control valve operating flow range is larger than Table 2 control valve operating flow range only for a
system pressure drop of 5 psi (108% vs 103%, 3,000 scfh), (114% vs 105%, 150,000 scfh), (116% vs 108%, 420,000
scfh), and is smaller for the rest of the system pressure drop cases (for 25 psi DPso, 58% vs 90%, 3,000 scfh), (66%
vs 95%, 150,000 scfh), (75% vs 93%, 420,000 scfh); (for 100 psi DPso, 33% vs 80%, 3,000 scfh), (42% vs 87%,
150,000 scfh), (55% vs 82%, 420,000 scfh case).
4. Effect of higher maximum flow limit (wider flow range):
Table 1 control valve selection is based on maximum flow being 110% of normal flow. In this section we will study
the control valve selection based on higher maximum flows: 120% and 150% of normal flow (system with wider
flow range). The results are shown in Tables 4a and 4b. Maximum flow and maximum system pressure drop are
increased proportionally to have a fair comparison.
Table 4a shows that when increasing maximum flow from 110% to 120% of normal flow, the same size globe
control valves are selected.

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Table 4b shows that when increasing maximum flow from 110% to 150% of normal flow, larger globe control valves
are required, the selected control valve for 204,546 scfh is able to operate at the minimum flow limit (50% of
normal flow), but for 4,091 scfh and 572,727 scfh, the selected control valves are not able to operate at minimum
flow for a system with a larger pressure drop (>139.5 psi or >186 psi). An option to avoid this problem is to use a
second smaller control valve for the low-flow service. Separate calculation shows that increasing allowable control
valve pressure drop does not improve the flow limitation at minimum flow at 20% valve opening by selecting
different control valves.

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5. Effect of compressor head variation with flow:

A centrifugal compressor curve shows compressor head variation with flow (Fig. 1). The shape of the compressor
curve depends on compression ratio, speed, type of gas and compressor design. In general, compressor head or
discharge pressure will increase when flowrate is decreased, or it will decrease when flowrate is increased. The
amount of head increase or decrease depends on the compressor curve and the operating point.

Fig. 1

A centrifugal compressor curve shows compressor

head variation with flow.

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Since the control valve is selected based on maximum flowrate and a valve opening close to 90% open, compressor
head will increase for 20% control valve opening and decrease for 90% control valve opening. The effects of
compressor head increases of 5 psi and 10 psi at 20% control valve opening and compressor head decreases of 5
and 10 psi at 90% control valve opening are listed in Table 5.

From these tables we see the effect of a compressor head increase on the globe control valve performance at 20%
valve opening (the lowest acceptable opening). As the compressor head increased (5 psi or 10 psi), flow also
increased, but slightly. The increase is about 3.2% to 0.1% (based on normal flow) for a 5 psi compressor head
increase and 5.9% to 0.1% for a 10 psi compressor head increase at different maximum system pressure drops. The
largest increase occurred for the system with the smallest system pressure drop (5 psi). Also shown is the effect of a
compressor head decrease on the globe control valve performance at 90% valve opening (the highest acceptable
opening). For a 5 psi compressor head decrease, percent flow (based on normal flow) decrease is about 35.8 to 0.3.
For a 10 psi compressor head decrease, percent flow decrease is about 120.8 to 0.3. The largest decrease again
occurred for the system with the smallest system pressure drop. This table also shows that selected globe control
valves are able to operate at a lower flow limit (50% of normal flow). Since selected control valves are based on the
upper flow limit, they are able to operate over the whole flow range. At the acceptable maximum valve opening
(90% open), the selected globe control valves may not be able to operate at the upper flow limit due to a
compressor head decrease; especially for a smaller control valve and system with a smaller system pressure drop
( <25 psi), or larger compressor head decrease (>10 psi).
Flow also increased slightly for a system with 50 psi or less system pressure drop. The increase is about 3.2 to 0.1%
(based on normal flow) for a 5 psi compressor head increase and 5.9 to 0.1% for a 10 psi compressor head increase.
The largest increase occurred for the system with the smallest system pressure drop (5 psi). Also shown is the
effect of a compressor head decrease on the globe control valve performance at 90% valve opening (the highest
acceptable opening). For a 5 psi compressor head decrease, percent flow (based on normal flow) decrease is about
35.8 to 0.3. For a 10 psi compressor head decrease, percent flow decrease is about 120.8 to 0.3. The largest
decrease again occurred for the system with the smallest system pressure drop. This table also shows that the
selected globe control valves are able to operate at a lower flow limit (50% of normal flow). Since the selected

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control valves are based on the upper flow limit, they are able to operate over the whole flow range. At the
acceptable maximum valve opening (90% open), the selected globe control valves may not be able to operate at the
upper flow limit due to a compressor head decrease; especially for a smaller control valve and system with a
smaller system pressure drop (<25 psi), or compressor head decrease larger than 5 psi.
B. For rotary control valves, maximum air flowrates of 420,000, 2,500,000 and 8,500,000 scfh are selected using
6 in., 12 in. and 20 in. lines respectively. Five system pressure drops (based on maximum flow) are selected: 5, 25,
50, 75 and 100 psi for each flow case.
The following factors are studied:
1. Allowable vapor control valve pressure drop, DPo?, at maximum flow, Q?o:
Allowable vapor control valve pressure drops of 5, 10 and 15 psi are selected. The control valve is selected close to
the maximum acceptable valve opening (90) with an equal-percentage characteristic. Table 6 shows the results.

From the table we see that, in general, a larger rotary control valve is required if the allowable control valve
pressure drop is smaller and vice versa. But sometimes the same control valve will be selected for different
allowable control valve pressure drops (see 420,000 scfh case). For 420,000 scfh flow with DPo = 5 psi, a 3 in.
rotary control valve is selected, but for the same service a 6 in. globe control valve is required.
2. Control valve performance at different system pressure drops, DPso:
This study is based on a control valve selected using an allowable control valve pressure drop of 5 psi at maximum
air flow (Table 6). At acceptable minimum and maximum control valve openings (20 and 90), flows through the
control valves in terms of percentage of normal flow are calculated for various system pressure drops (based on
maximum flow). Results are listed in Table 7 for maximum air flows of 420,000 and 8,500,000 scfh. Our target is
that the control valve is able to operate over 50 to 110% of normal flow.

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From this table we see that selected rotary control valves are able to operate over 50% to 110% flow range,
operating flow range is 114% to 107% of normal flow for a system pressure drop of 5 psi and 103% to 93% of
normal flow for a system pressure drop from 25 psi to 100 psi. Compared to a globe control valve (Table 2,
420,000 scfh), a rotary control valve has about the same flow range at 5 psi system pressure drop (107.3 vs
107.8%), but it has wider flow range for the rest system pressure drop cases (10399% vs 9382%). A rotary
control valve has a wider flow range than a globe control valve, especially for the system with a larger system
pressure drop (> 5 psi).
3. Select control valve away from the acceptable maximum control valve opening:
Table 7 control valves are selected close to the maximum opening (90 open). Performance of control valves
selected away from the maximum opening is listed in Table 8.

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Comparing the rotary control valve performance to the corresponding one in Table 7, it is seen that a larger control
valve will be selected if control valve selection is away from the maximum acceptable opening (higher capital cost).
Comparing the operating ranges of Table 8 control valves to those of Table 7, Table 8 control valve operating range
is larger for a system pressure drop of 5 psi (133% vs 107%, 420,000 scfh), (122% vs 114%, 8,500,000 scfh), and is
smaller for the other system pressure drops (for 25 psi DPso,92% vs 103%, 420,000 scfh), (98% vs 100%,
8,500,000 scfh); (for 50 psi DPso, 81% vs 101%, 420,000 scfh), (91% vs 97%, 8,500,000 scfh); (for 75 psi DPso,
77% vs 101%, 420,000 scfh), (87% vs 95%, 8,500,000 scfh); (for 100 psi DPso, 75% vs 99%, 420,000 scfh), (86% vs
93%, 8,500,000 scfh). Selected rotary control valves are still able to operate at design flow range (50% to 110%
normal flow).
4. Effect of higher maximum flow limit (wider flow range):
Table 6 control valve selection is based on maximum flow as 110% of normal flow. In this section we will study
control valve selection based on higher maximum flows: 120% and 150% of normal flow (system with a wider flow
range). The results are shown in Tables 9a and 9b. Maximum flow and maximum system pressure drop are
increased proportionally to have a fair comparison.
Table 9a shows that when increasing maximum flow from 110% to 120% of normal flow, a larger control valve (4
in. vs 3 in.) is selected for 420,000 scfh flow, but the same control valve is selected for 8,500,000 scfh flow.

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Table 9b shows that when increasing maximum flow from 110% to 150% of normal flow, larger rotary control
valves are required. Selected rotary control valves are able to operate at minimum flow (50% of normal flow) for all
the system pressure drops.

5. Effect of compressor head variation with flow:

The effect of compressor head increases of 5 and 10 psi at 20 valve opening and compressor head decreases of 5

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and 10 psi at 90 valve opening are listed in Table 10.

From these tables, we see the effect of compressor head increase on rotary control valve performance at 20 valve
opening (the lowest acceptable opening). As the compressor head increased (5 psi or 10 psi), flow also increased,
but slightly. The increase is about 1.8% to 0% (based on normal flow) for a 5 psi compressor head increase and
2.0% to 0% for a 10 psi compressor head increase at different system pressure drops. The largest increase occurred
for the system with a 5 psi system pressure drop. Also shown is the effect of a compressor head decrease on rotary
control valve performance at 90 valve opening (the highest acceptable opening). For a 5 psi compressor head
decrease, percent flow (based on normal flow) decrease is about 38.7 to 0.1. For a 10 psi compressor head decrease,
percent flow decrease is about 122.4 to 0.3. The largest decrease occurred for the system with a 5 psi system
pressure drop. This table shows that the selected rotary control valves are able to operate at the lower flow limit
(50% of normal flow). Since the selected control valves are based on the upper maximum flow limit, they are able
to operate over the whole flow range. At the acceptable maximum valve opening (90 open), for 420,000 scfh, the
selected rotary control valve is able to operate at the maximum flow limit for the system with the larger system
pressure drop (>75 psi) and smaller compressor head drop (5 psi). For 8,500,000 scfh, the selected rotary control
valve is able to operate at the maximum flow limit with a system pressure drop >25 psi and larger compressor head
drop (10 psi). Therefore, a larger rotary control valve is less sensitive to compressor head decrease at 90 opening.
Discussion.
1. The process engineer should provide allowable control valve pressure drop at minimum, normal and maximum
flows, so that the instrument engineer is able to select a proper control valve for the full operating range. For a
system without a compressor, often only system pressure drop at normal flow is available from hydraulic study.
But Eq. 2 can be used to estimate the system pressure drop at maximum flowrate. Then, allowable control valve
pressure drops at maximum and minimum flowrates can be estimated using Eq. 1. For a system with a compressor,
often the system pressure drop at maximum flow is available since the compressor hydraulic calculation is based
on maximum flow.

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2. To minimize the operating cost, it is recommended to assign a minimum allowable pressure drop for the control
valve at maximum flow. It is also recommended to size the control valve close to maximum acceptable valve
opening, since it will result in a smaller control valve (less capital cost) and wider flow range.
If there are several branches between the compressor and destination equipment, the previous rule should apply to
the critical branch that will result in a smallest compressor discharge pressure.
3. In general, a rotary control valve has a wider flow range (10792% normal flow) than a globe control valve (93
82% normal flow) for a system pressure drop >5 psi. For a system pressure drop of 5 psi, their flow range is about
the same (107% vs 108%).
4. For a system with a wider flow range (50% to 150% of normal flow), a globe control valve sometimes is not able
to cover the minimum flow, but the rotary control valves do not have this problem.
5. In this study, selected globe control valves are able to turn down the flow to 18 to 31% of normal flow at 20%
control valve opening, assuming the compressor head increase is 10 psi. For selected rotary control valves at 20
opening and a 10 psi compressor head increase, flow can be turned down to 7 to 18% of normal flow.
Selected globe control valves are still able to pass 110% normal flow at 90% control valve opening if system
pressure drop is greater than 25 psi. Selected rotary control valves at 90 opening are able to pass 110% normal
flow if the control valve size is large (>3 in.), system pressure drop is large (>25 psi) and the compressor head
decrease is less (<10 psi).
Since the control valve is selected based on maximum flow and close to acceptable maximum control valve
opening, the selected control valve will be guaranteed to be able to operate at maximum flow.
6. The analysis in this study assumes that the hydraulic calculation matches actual plant operation. Often, pressure
drops of equipment or instruments are over estimated in hydraulic calculation. This will cause more pressure drop
available for the control valve in real operation. HP

LITERATURE CITED
1 F. C. Yu, "Easy way to estimate realistic control valve pressure drops," Hydrocarbon Processing, August 2000, p.

4548.
2 Control Valve Handbook, 3rd edition, Fisher Controls International, Inc., 2001.

The author
Frank C. Yu is a senior process engineer at Jacobs Engineering Group, Inc., Houston, Texas. He
specializes in process design. Dr. Yu holds a BS degree from Tunghai University, an MS degree
from the University of Massachusetts, and a PhD from the University of Texas at Austin, all in
chemical engineering.

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