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Control Valve Sizing and Selection in Pulp and Paper - Getting it Right
Abstract - When selecting a control valve for a pulp and • Capacity vs. cost
paper application, it is important to have a basic • Noise and cavitation
understanding of control valve sizing and selection and • Nature of flowing media
how it affects control valve performance. Optimizing • Dynamic performance
control valve selection can improve loop dynamics and
alleviate problems such as cavitation, flashing, and noise. A. Pressure Ratings
This paper will review guidelines and apply industry
standard sizing models to applications widely seen
Body pressure ratings ordinarily are considered according
throughout the industry to illustrate the valve selection
to ANSI pressure classes - the most common ones for
process and how it can improve efficiency and reliability
carbon steel and stainless steel being Classes 150, 300 and
within a pulp and paper mill.
600. For a given body material, each ANSI Class corresponds
to a prescribed profile of maximum pressures that decrease
I. INTRODUCTION with temperature according to the strength of the material.
Each material also has a minimum and maximum service
Process plants such as a pulp and paper mill consist of
temperature based upon loss of ductility or strength. Table 1
hundreds, or even thousands, of control loops all networked
and Table 2 below illustrate these differences between carbon
together to produce a product to be offered for sale. Each of
steel and stainless steel materials.
these control loops is designed to control a critical process
variable such as pressure, flow, level, temperature, etc. , within
TABLE 1
a required operating range to ensure the quality of the end
PRESSURE-TEMPERATURE RATINGS FOR STANDARD
product. These loops receive, and internally create,
CLASS ASTM A216 GRADE WCC VALVES
disturbances that can detrimentally affect the process
variable. Interaction from other loops in the network provides
disturbances that can influence the process variable. To
reduce the effect of these load disturbances, sensors and
transmitters collect information regarding the process variable
and its relationship to a desired set point. A controller then
processes this information and decides what must occur in
order to get the process variable back to where it should be
after a load disturbance occurs. When all measuring,
comparing, and calculating are complete, the strategy
selected by the controller is implemented via some type of
final control element. The most common final control element
in the process control industries is the control valve.
C, End Connections
D, Shutoff Capability
precautions in seat material selection, seat preparation and different characteristic by utilizing a nonlinear (i. e. ,
seat load are necessary to ensure success. characterized) positioner-actuator combination. The limitation
of this approach lies in the positioner's frequency response
E. Material Selection and phase lag compared to the characteristic frequency of the
process. Although it is common practice to utilize a positioner
Material compatibility and durability is a more complex on every valve application, each application should be
consideration. Variables may include corrosion by the process reviewed carefully. There are certain examples of high gain
fluid, erosion by abrasive material, flashing, cavitation or processes where a positioner can hinder valve performance.
pressure and temperature requirements. In pulp and paper for
example, for chlorine dioxide processes, Hastelloy or Titanium I. Noise
need to be considered. The piping material usually indicates
the body material. However, because the velocity is higher in Noise has always been present in control valves. It is a
valves, other factors must be considered. When these natural side effect of the turbulence and energy absorption
variables are included, often valve and piping materials will inherent in control valves. The major problem with industrial
differ. The trim materials, in turn, are usually a function of the noise is its effect on humans. The U. S. Occupational Safety
body material, temperature range and qualities of the fluid. and Health Act (OSHA) established maximum permissible
When a body material other than carbon, alloy, or stainless noise levels for all industries whose business affects interstate
steel is required, use of an alternate valve type, such as lined commerce. These standards relate allowable noise levels to
or bar stock, should be considered. the permissible exposure time. Notice in the table below that
the maximum permissible levels depend upon the duration of
F. Flow Characteristic exposure. For example, the maximum sound level a person
should be exposed to for an eight hour day is 90 dBA. These
The next selection criterion, "inherent flow characteristic", maximum sound levels have become the accepted noise
describes the relationship between flow capacity (Cv) and exposure standard foremost regulatory agencies. Thus, they
control valve travel. Typical characteristics are quick-opening, have become the standard by which much noise generating
linear, and equal-percentage. The quick-open characteristic, equipment has been specified and measured.
as its name suggests, delivers capacity rapidly at low travels
and slows as travel increases. The linear characteristic, as its TABLE 3
name suggests, delivers a linear relationship between flow MAXIMUM SOUND PRESSURE FOR DURATION OF
capacity and travel. The equal percentage delivers flow EXPOSURE
capacity at an increasing rate in relationship to travel. The Duration of Exposure Maximum Sound Pressure
equal percentage characteristic is very common due in part to (Hours) (dBA)
loop characteristics based on fluid dynamics. Control valve 16 85
response to loop signal changes and the resultant flow and 8 90
related process variable changes significantly affect overall 4 95
loop response (gain). It is very common for available energy 2 100
to drive flow across a control valve (measured as differential 1 105
pressure) to decrease with an increasing loop flow. This Y, 110
causes loop response (gain) to be slower at higher flow rates. Y. 115
The equal percentage characteristic offsets this by increasing
the rate of change of flow capacity as travel increases. Noise reduction is accomplished in two general ways:
the mixture is greater than the vapor pressure as it exits the other factors in selecting control valves, and general selection
valve, the vapor phase will be thermodynamically unstable principles are not always the best choice. Process conditions,
and will revert to a liquid. The entire liquid-to-vapor-to-liquid physical fluid phenomena, among numerous other criteria
phase change process is known as "cavitation, " although it is must be considered in order to obtain the best possible
the vapor-to-liquid phase change that is the primary source of solution. Many applications are beyond that of general
the damage. During this phase change a mechanical attack service, and there are of number of selection criteria that must
occurs on the material surface in the form of high velocity be considered when dealing with these sometimes severe
micro-jets and shock waves. Given sufficient intensity, flows. Special considerations may require out-of-the-ordinary
proximity, and time, this attack can remove material to the valve solutions; there are valve designs and special trims
point where the valve no longer retains its functional or available to handle high noise applications, flashing,
structural integrity. cavitation, high pressure, high temperature and combinations
of these conditions.
The possibility of cavitation occurring in any liquid flow
application should be investigated by checking for the III. VALVE SIZI NG AND SELECTION
following two conditions:
A . Liquid Sizing
• The service pressure differential is approximately
equal to the allowable pressure differential. The flow equations used for sizing have their roots in the
• The outlet pressure is greater than the vapor fundamental equations, which describe the behavior of fluid
pressure of the fluid. motion. The two principle equations include the:
If both of these conditions are met, the possibility exists • Energy equation
that cavitation will occur. Because of the potentially damaging • Continuity equation
nature of cavitation, sizing a valve in this region is not
recommended. Special purpose trims and products to control The energy equation is equivalent to a mathematical
cavitation should be considered. Because of the great statement of the first law of thermodynamics. It accounts for
diversity in the design of this equipment, it is not possible to the energy transfer and content of the fluid. For an
offer general guidelines for sizing valves with those incompressible fluid (e. g. a liquid) in steady flow this equation
specialized trims. can be written as:
L. Conclusion
From equations (10) and (11), it can be seen that the velocity
(at location two) is proportional to the square root of the
Thus, as the fluid passes through the restriction, the velocity pressure drop. Volume flow rate can be determined knowing
increases. Below, equation (2) has been applied and elevation the velocity and corresponding area at any given point so that:
changes have been neglected (again using upstream
conditions as a reference):
Now letting: • Use N1 if sizing the valve for a flow rate in volumetric
units (gpm or m3/h).
• Use N6 if sizing the valve for a flow rate in mass units
And defining: (lb/h or kg/h).
ΔP
17
particular sizing problem, refer to the appropriate factor
determination section(s) located in the text proceeding step
six.
0.96 0.28
1. Specify the variables required to size the valve as follows:
• Desired design
• Process fluid (water, oil, etc.)
• Appropriate service conditions Q or w, P1, P2 or ∆P,
T1, Gf, Pv, and Pc
TABLE 4
SYMBOLS AND MEANINGS
TABLE 5
EQUATION CONSTANTS
TABLE 6 For valve size, since the pipe diameter is 3 inches, consult the
PROCESS DATA FOR PULP STOCK SIZING Cv flow data tables for the desired valve model to find a
suitable size that can accommodate the Cv's calculated
previously. The smallest recommended size would be 1. 5
inches.
D. Actuator Selection
2) Fail-safe Requirements
80
Cvnormal In 28.48
0.993 * ,,8
= =
Some loops demand specific valve action if the power
source fails. This is due to safety reasons or for protection of
110 equipment. Actuator designs are typically available with a
Cvmax . 11'> 32.56
0.993 * ,,12
= =
choice of failure mode between failing open, failing closed, or
holding last position.
Now LlPmax must be calculated to see if there is choked flow in
any of the conditions. First the liquid critical critical pressure 3) Torque or Thrust Requirements
ratio factor (FF) must be calculated:
An actuator must have sufficient thrust or torque for the
FF =
r;-
0.96 - 0.28 �3"2'00 = .9553 prescribed application. In some cases this requirement can
dictate actuator type as well as power supply requirements.
For instance, large valves requiring a high thrust may be
For the rated liquid pressure recovery factor (FL), a value of limited to only electric or electro-hydraulic actuators due to a
0. 6 will be used in this example because this is typical for lack of pneumatic actuators with sufficient thrust capability.
rotary valves. In control applications for pulp service, Conversely, electro-hydraulic actuators would be a poor
segmented V-notch ball valves are usually the best option choice for valves with very low thrust requirements. The
because the shearing action between the V-notch ball and ball matching of actuator capability with valve body requirements
seal promote smooth, non-clogging operation. With this is best left to the control valve manufacturer as there are
information and using equation (17), the following are considerable differences in frictional and fluid forces from
calculated: valve to valve.
LlPmax(norm) = 0.62(26.7 - 0.9553 * 0.9) = 9.30 psi Knowledge of the required actuator functions will most
clearly define the options available for selection. These
LlPmax(norm) = 0.62(35.4 - 0.9553 * 0.9) = 12.43 psi
functions include the actuator signal (pneumatic, electric,
etc. ), signal range, ambient temperatures, vibration levels,
operating speed, frequency, and quality of control that is
Comparing these LlPmax values to the actual LlP's of the
required. Signal types are typically grouped as such:
process at 4, 8, and 12 psi respectively, since the actual LlP
values are lower, choked flow is not an issue for this
• Two-position (on-off)
application. However, it is important to note that FL has a large
• Analog (throttling)
impact on LlPmax so the correct FL value must be used when a
specific valve has been selected to check for choked flow. • Digital
• Compatibility with instrument signal dP 130 psi 170 psi 120 psi 150 psi 120 psi 185-195 psi
• Better static and dynamic performance to ensure Q 1500 Qpm 1500 Qpm 1500 Qpm
The control valve is one of the control components that Application Data
actually touch the process fluid. Control loop performance is Fluid: Chlorine dioxide solution
highly dependent on the ability of the control valve to deliver Typical Size: NPS 1 to 6
the response the rest of the loop is calling for. Fluid process
control applications vary widely in what is required to optimize Considerations:
performance and profitability. Matching application
requirements with available control valve designs and options The pressure drop is not very high and neither is the
can provide for greater probability for optimal and profitable temperature. The most important thing to consider is the
process operation. Some common applications in pulp and material selection since chlorine dioxide is a very erosive fluid.
paper will be discussed to illustrate the valve selection
process. • For CI02 into stock (>3000 ppm): Titanium
• For residual (1000 to 3000 ppm): 254 SMO
A. Digester Switching Valve
• For caustic towers «1000 ppm): Stainless steel
Liquor is extracted from different areas of the digester and
sent to the bottom circulation heaters to cook the wood chips.
Valves fully stroke every 90 seconds to cause a flow reversal C. Main Steam Pressure Reducing Valve
through the extraction screens, preventing the screens from
plugging the chips and fiber. This valve is located downstream of the recovery and
power boilers and is used to bridge the high, medium, and low
pressure headers. It reduces the steam pressure and
temperature to be usable in the plant. Typically,
desuperheaters are installed downstream.
Application Data
Fluid: High pressure steam
Pressure: Can be over 2000 psig
Temperature: 225-350° F
Considerations:
V. CONCLUSION
The control valve is an important part of a process loop in
a process plant. Because of this, it is essential to know the
control valve sizing and selection process. This knowledge will
help optimize performance, improve efficiency, and reduce
waste in a plant.
VI. REFERENCES
[1] ASME/ANSI B16.1, Cast Iron Pipe Flanges and Flanged
Fittings.
[2] ASME/ANSI Standards B16.34, Valves - Flanged,
Threaded, and Welding End
[3] Emerson Process Management, Fisher Controls, Control
Valve Sourcebook - Pulp & Paper