CONTROL VALVES

Part 2
Prepared by : Fred Tarhandeh
Reviewed : Ezatolah Mardasi
 TPCP Ruler
Technology Class: Base INSTRUMENT & PROCESS CONTROL “COMPETENCE MATRIX”

Ref Competence levels: Awareness Knowledge Skill Level Advanced

.
Nr.
Technology:
5 Control Valves applications:

The knowledge and skill to select and Ability to The ability The Skill -The skill to master
specify the appropriate body assembly -list the most common -to select the –to judge alternatives in body all aspects of valve
of a control valve in order to satisfy the physical properties of a appropriate control construction, selection and on top
actual process application. It includes control-valve valve body assembly -to consider the required and of that to critical
the selection of valve options to handle -to list the basic for all forthcoming achieved turndown ratio’s, examine process
highly erosive applications, the selection process parameters process conditions, -to judge maintenance aspects conditions, provided
of special materials and the that are used in -to specify body based on practical experience with by others with
specification of requirements for low- control-valve sizing. materials with respect aspects such as valve stand-time respect to dynamic
noise applications. to erosion/ corrosion, (refers also to material-selection), and static pressure
Skills to understand the underlying -to perform a -to consider dirt-handling and losses.
principles of control valve sizing as a computerised valve- maintenance accessibility.
part of a plant system with dynamic and sizing calculation and -to specify the internationally defined
static gains/losses are needed. to select the most valve leakage factor, acceptable for
Skills to master its application in actual suitable valve adequate plant operation.
practise for all process media are an construction including
integral part of the technology. the selection of an
actuator.

2
 Contents
Summary of material presented on Control Valve Part 1
Definition and Terminology

Applications
Types of Control Valves and Their Application
General
Control Valves for Special Applications
Severe Service
Cryogenic Service
Cavitation and Flashing
Control Valve Noise
Sizing & Selection
Sizing
Actuator selection
Material selection
Codes & Standards
References
3 Sample Data sheet and Thermodynamic Critical Constants
SUMMARY OF CONTROL
VALVE PART 1
PRESENTATION
 SUMMARY OF CONTROL
VALVE PART 1
PRESENTATION
 Since some parts of the control valve has already been
presented in Control Valve Part 1, therefore those material will
not be repeated. Briefly the covered material Control Valve Part
1 are:
 Some Definition & Terminology
 Major Components of The Control Valve
 Body and Actuator Assembly
 Type of Guiding
 Top & Bottom Guided
 Cage Guided
 Top and Port Guided

5
 SUMMARY OF CONTROL
VALVE PART 1
PRESENTATION (cont..)
 Balanced and Unbalanced Trim
 Type of The Body
 Angle
 Ball
 Butterfly
 Gate
 Globe
 Type of the actuators
 Electric
 Hydraulic
 Pneumatic
 Accessories

6
Definition and
Terminology
Definition and Terminology

Definition and Terminology

 Actuator
– A pneumatic, hydraulic, or electrically powered device which
supplies force and motion to position a valve’s closure member at
or between the open or closed position.
 Bench set
– The shop calibration of the actuator spring range of a control valve,
to account for the in-service process forces.
 Cv
– By definition,the valve flow coefficient, Cv, is the number of U.S.
gallons per minute of water that will pass through a given flow
restriction with a pressure drop of one psi

8
Definition and Terminology

Definition and Terminology

 Cavitation
– A two-stage phenomenon of liquid flow. The first stage is the formation
of vapor bubbles within the liquid system due to static pressure of fluid
falling below the fluid vapor pressure; the second stage is the collapse
or implosion of these cavities back into an all-liquid state as the fluid
decelerates and static pressure is recovered
 Choked flow
– A condition wherein the flow rate through a restriction does not increase
when the downstream pressure is decreased at a fixed inlet pressure.
 Electrohydraulic actuator
– A device that converts electrical energy to hydraulic pressure and into
motion.

9
 Definition and Terminology

Definition and Terminology

 Extension bonnet
– A bonnet with a packing box that is extended above the usual height so to
maintain the temperature of the packing within its operating limits.
 Fail-Closed
– A condition wherein the valves closure member moves to a closed position
when the actuating energy source fails.
 Fail-Open
– A condition wherein the valve closure member moves to an open position
when the actuating energy source fails.
 Fail-Safe
– A characteristic of a valves and its actuator, which upon loss of actuating
energy supply, will cause a valve closure member to be fully closed, fully
open, or remain in the last position, whichever position is defined as
necessary to protect the process.

10
 Definition and Terminology

Definition and Terminology

 Flashing
– If pressure at the valve outlet remains below the vapor pressure of the
liquid, the bubbles will remain in the downstream and the process is said to
have flashed
 Hand jack
– A manual hydraulic or mechanical override device, using a lever, to stroke
a valve or to limit its travel.
 Handwheel
– A mechanical manual override device, using a rotary wheel, to stroke a
valve or to limit its travel.
 Hardness
– Resistance of metal to plastic deformation, usually by indentation.
Resistance of plastics and rubber to penetration of an indentor point into its
surface
 Hydraulic actuator
– A fluid device which converts the energy of an incompressible fluid into
motion.

11
 Definition and Terminology

Definition and Terminology

 Manual override
– See “Hand Jack” and/or “Handwheel.”
 Modulation
– The action of a control valve to regulate fluid by varying the position of
the closure member.
 Pneumatic actuator
– A device that converts the energy of a compressible fluid, usually air,
into motion.
 Positioner
– A positioner controller (servomechanism) that is mechanically
connected to a moving part of a final control element or its actuator and
that automatically adjusts its output to the actuator to maintain a desired
position in proportional to the input signal.

12
 Definition and Terminology

Definition and Terminology

 Rangeability
– The ratio of the largest flow coefficient (C v) to the smallest flow coefficient
(Cv) within which the deviation from the specified flow characteristic does not
exceed the stated limits. A control valve that still does a good job of
controlling when flow increases to 100 times the minimum controllable flow
has a rangeability of 100 to 1. Rangeability can also be expressed as the
ratio of the maximum to minimum controllable flow rates.
 Rated Cv
– The flow coefficient (Cv) of the selected valve at full travel
 Rated Travel
– The distance of movement of the closure member from the closed position
to the rated full-open position. The rated full-open position is the maximum
opening recommended by the manufacturers.
 Resolution
– The minimum possible change in input required to produce a detectable
change in the output when no reversal of the input takes place. Resolution is
typically expressed as a percent of the input span.

13
 Definition and Terminology

Definition and Terminology

 Repeatability
– The closeness of agreement among a number of consecutive
measurements of the output for the same value of the input under the
same operating conditions, approaching from the same direction, for full
range traverses. It is usually measured as a non-repeatability and
expressed as repeatability in percent of span.
 Seat Leakage
– The quantity of fluid passing through a valve when the is in the fully
closed position with pressure differential and temperature as specified.
 Travel
– The movement of the closure member from the closed position to an
intermediate or rated full open position.

14
 Definition and Terminology

Definition and Terminology

 Trim
– The internal components of a valve that modulate the flow of the
controlled fluid.
 Trunnion
– Shaft extension(s) on a rotary closure member used to locate and
support it with bearings within the valve body.
 Turndown
– See “Rangeability.”

15
APPLICATIONS
 APPLICATIONS

Types of Valves and Their

Application
General
 If the application allows, valves with a rotating spindle are preferred to
linear motion valves for reasons of:
 Robustness
 Capacity
 Turndown
 Fugitive emissions
 Control valves shall be selected in accordance with the requirements
of the piping class.
 Cadmium plating or galvanizing shall not be used for any component
of the valve assembly or its accessories.

17
 APPLICATIONS

Types of Valves and Their

Application
 In applications/locations where freezing may occur, valve stems,
solenoid valves and other mechanical moving parts shall be protected
against ice formation. The principle shall approve the method of
protection.
 Linear motion valves shall be installed with their actuator stem in the
vertical position.
 Control valves shall be installed with sufficient clearance around the
actuator and valve body to allow the control valve to dismantled without
the valve body being removed from the pipe.
 They shall be sufficient clearance to lift and remove the valve. Control
valves shall be located so that they are accessible for hoisting
equipment where needed.

18
 APPLICATIONS

Types of Valves and Their

Application
 Throttling control valves should not be used if tight shut-off Class V or
VI is required as per IEC 60534-4, since these shut-off classes cannot
be maintained over a prolonged period. If a Class V and VI shut-off is
required, a dedicated on-off TSO valve (e.g. ball or high performance
butterfly valve) should be installed in series with the throttling control
valve.
 The necessity of assigning such shut-off classes shall be examined
with care. For shut-off class VI, rotary valves are preferred.
 For depressuring services, two valves in series shall not be employed.

19
 APPLICATIONS

Types of Valves and Their

Application

Rotary Valves:
 Valves with Eccentric Plug or Segmented Ball
 Ball Valves
 Butterfly Valves

20
 APPLICATIONS

Types of Valves and Their

Application
Valves with Eccentric Plug or Segmented Ball

Rotary valves of the eccentric plug or segmented ball type

should be considered as the first choice

Ball Valves
Ball valves shall be considered for on-off service
Ball valves for use in erosive (e.g. slurry) service etc. should be
equipped with a scraper type of seat construction
Ball valves, i.e. valves without specially designed control related
internals, shall not be selected for throttling service without the
approval of the Principal.
Unless equipped with a special trim, i.e. anti-cavitation or
low-noise design, certain ball valves may be unsuitable for high
21 differential pressures.
 APPLICATIONS

Types of Valves and Their

Application
Butterfly Valves

Butterfly valves shall be considered for the following circumstances:

If the required size would make it economically attractive (usually
due to a high flow rate with a low pressure drop.
If eccentric plug/segmented ball or globe valves are not suitable
For corrosive services, where body lining of globe valves becomes
economically unattractive.
Double or triple eccentric butterfly valves, also known as high
performance (HP) butterfly valves, can be used in Class V or VI TSO
applications in accordance with IEC 60534-4. They can handle high
temperatures and high differential pressures.

22
 APPLICATIONS

Types of Valves and Their

Application

Linear Motion Valves:

 Globe Valves
 Plug Valves
 Angle Valves
 Diaphragm Valves
 Gate Valves
 Rising Stem Ball Valves

23
 APPLICATIONS

Types of Valves and Their

Application
Globe Valves
Two-way globe valves
 If rotary valves cannot be used, globe valves should be considered
as the first choice
Three-way globe valves
 Each flow path shall be sized separately for three way globe
valves
 Except for instrument air dryers, the application of three-way globe
valves requires the approval of the Principal
Plug Valves

Plug valves should be considered for special applications such as

throttling control in slurry service. The use of plug valves requires
24 the approval of Principal.
 APPLICATIONS

Types of Valves and Their

Application
Angle Valves
Angle valves should be considered for:
 hydrocarbon services where coke may form
Erosive service, e.g. slurries
Flashing service
Application where solid contaminants might settle in the body
of a globe valve
 liquid service where high differential pressure prevails.
Diaphragm Valves
 Diaphragm valves should only be considered for on/off
applications in slurry service. The use of diaphragm valves
requires the approval of the Principal
 Diaphragm valves shall be in accordance with MESC SPE
25 77/108
 APPLICATIONS

Types of Valves and Their

Application
Gate Valves
 Gate valves should only be considered for remotely operated
on-off applications, where a fail-safe action is not required.
 They are normally equipped with an electric actuator or
hydraulic actuator.
 Typical applications are storage tank isolating valves, remotely
operated on/off valves on blenders, pump suction shut-off
services, and shut-off services on wellheads in oil and gas
production facilities.
 For gate type control valves, the same requirements shall
apply as for gate on-off valves, listed in accordance with PTS
31.38.01.12

26
 APPLICATIONS

Types of Valves and Their

Application
 Rising Stem Ball Valves

 Rising stem ball valves are particularly suitable for dryer

applications
They operate with the aid of a linear actuator, which initially lifts and
then rotates the ball valve, by means of a large pitch helical form.
 They shall be equipped with pneumatic actuators
The breakaway torque shall be carefully calculated so that the
minimum instrument air supply pressure will suffice under all service
conditions and the actuators shall be sized accordingly.

27
 APPLICATIONS

Control Valves for Special

Applications
1. LOW TEMPERATURE SERVICE
 Control valves in services with a design temperature between
0oC and minus 50oC shall, in addition to the specification in the
requisition, comply with MESC SPE 77/209.
 Control valves in services with a lower design temperature
below minus 50oC shall, in addition to the specification in the
requisition, comply with MESC SPE 77/200.

2. VACUUM SERVICE
 Control valves in services with a design pressure below 1.0 bar
(abs) shall, in addition to the specification in the requisition,
comply with MESC SPE 77/201.

28
 APPLICATIONS

Control Valves for Special

Applications
3. STEAM SERVICE
 Control valves in steam service with ASME rating class 300
and higher shall, in addition to the specification in the
requisition, comply with MESC SPE 77/202.
4. HYDROGEN SERVICE
 Control valves in service containing hydrogen with a partial
pressure of 7 bar (abs) and above shall, in addition to the
specification in the requisition, comply with MESC SPE 77/203
5. HYDROFLUORIC ACID (HF) SERVICE
 Control valves in HF service shall, in addition to the
specification in the requisition, comply with MESC SPE 77/204.

29
 APPLICATIONS

Control Valves for Special

Applications
6.OXYGEN SERVICE INCLUDING HIGH PRESSURE AIR
SERVICE
 Any medium containing more than 21% oxygen by volume or a
system with air at a pressure above 50 bar (g) is to be considered as
oxygen service. For control valves in oxygen service, PTS
31.10.11.31 and MESC SPE 77/205 shall apply.
7. ETHYLENE OXYDE SERVICE
 Control valves for ethylene oxyde service shall, in addition to the
specification in the requisition, comply with MESC SPE 77/207.
8. CHLORINE SERVICE
 Control valves for chlorine service shall, in addition to the
specification in the requisition, comply with MESC SPE 77/206.

30
 APPLICATIONS

Control Valve for Special

Applications
9. “SOUR” OR “WET H2S” SERVICE
 “Sour” or “Wet H2S” services are defined in PTS 31.38.01.11. The
materials of those valve parts which under whatever process condition
are in contact with process water or aqueous condense shall comply
with the requirements of NACE MR0175 and the relevant piping class.
 NACE MR0175 requirements shall apply to the control valve and
pressure-retaining bolting (even if not directly exposed to the process
fluid).
10. VALVES IN HEAT TRANSFER FLUID SERVICE.
 Gate and globe type control valves for heat transfer fluid service shall,
in addition to the specification in the requisition, comply with MESC
SPE77/208.

31
 APPLICATIONS

Severe Service
 Cavitation
 Flashing
 Noise
 Steam Conditioning

For all above applications valves are utilized with different

design:
 Multi-stage design with harden material:

– Drag disk by CCI

– Multi Labyrinth Trim by Severn Glocon
– Other Manufacturer Different Design
– Angle Valve

32
 APPLICATIONS

Severe Service
 With the concept of a multi-plate stack established in order to provide
to the increased flow capacity for a given valve size the challenge was
then to incorporate as many twists and turns into the fluid path.
 This was achieved by making the fluid move in both vertical and
horizontal radial direction concurrently.
 The right angle turns and expanding flow passages removes the kinetic
energy from the fluid while lowering the pressure in a velocity controlled
manner.
 Abrupt increases are avoided.
 Each flow stream is made up of many right angle turns.
 Each right angle flow turn adds to the accumulating controlled pressure
reduction.

33
 APPLICATIONS

Severe Service

Plan sectional of a concentric multi cage trim MLT 3D view

34
 APPLICATIONS

Cryogenic Service
Valve
 Cryogenics is the science dealing with materials and processes at
temperature below minus 150oF (-101oC).
 For control valve applications in cryogenic services, many of the
same issues need consideration as with high temperature control
valves.
 Plastic and elastomeric components often cease to function
appropriately at temperature ranges, components such as packing
and plug seals require special consideration.
 For plug seals, a standard soft seal will become very hard and less
pliable thus not providing the shut-off required from a soft seat.
 Special elastomers have been applied in these temperatures but
require special loading to achieve a tight seal.

35
CAVITATION AND FLASHING
 Cavitation and
CAVITATION AND FLASHING

Flashing
 Chocked Flow Causes Flashing and Cavitation
 The IEC liquid sizing standard calculates an allowable sizing
pressure drop, Pmax. If the actual pressure drop across the valve,
as defined by the system conditions of P1 and P2, is greater than
Pmax then either flashing or Cavitation may occur

37
 CAVITATION AND FLASHING

Cavitation And Flashing

Flashing
If pressure at the valve outlet remains below the
vapor pressure of the liquid, the bubbles will remain
in the downstream and the process is said to have
flashed. Flashing can produce serious erosion
damage to the valve trim parts.

Cavitation
On the other hand, if downstream pressure
recovery is sufficient to raise the outlet
pressure above the vapor pressure of the liquid,
the bubbles will collapse, or implode,
producing Cavitation.
38
 CAVITATION AND FLASHING
Comparison of Pressure
Profile for high and Low
Recovery Valves

39
 CAVITATION AND FLASHING

Valve Selection for

Flashing Service
 Flashing damage is characterized by a smooth, polished appearance
of the eroded surfaces. To review, flashing occurs because P2 is less
than Pv.
 P2 = the pressure downstream of the valve and is a function of the
downstream process and piping.
 Pv = a function of the fluid and operating temperature.
 Therefore, the variables that define flashing are not directly controlled
by the valve. This further means there is no way for any control valve
to prevent by the valve the best solution is to select a valve with proper
geometry and materials to avoid or minimized damage.

40
 CAVITATION AND FLASHING

Valve Selection for

Flashing Service
 In general erosion is minimized by:
 prevent or reducing the particle (liquid droplets in
this case) impact with the valve surfaces.
 Making those surfaces as hard as possible.
 Lowering the velocity of the erosive flow.

41
 CAVITATION AND FLASHING

Valve Selection for

Cavitation Service
 Cavitation damage is characterized by a rough, cinder-like appearance of
the eroded surface. It is distinctly different from the smooth, polished
appearance caused by the erosion of flashing. Cavitation can be treated
by several method:

1 The first is to eliminate the Cavitation and thus the damage by

managing the pressure drop. If the pressure drop across the valve
can be controlled such that the local pressure, then no vapor
bubbles will form. Without vapor bubbles to collapse, there is not
Cavitation. To eliminate Cavitation the total pressure drop across
the valve split, using multiple - stage trims, into smaller portions.
Each of this small drops keeps its vena contracta pressure above
the vapor pressure so no vapor bubbles are formed

42
 CAVITATION AND FLASHING

Valve Selection for

Cavitation Service
The second method does not eliminate the cavitation but
2 rather minimizes or isolates the damage much the same as
with flashing solutions. This method aims to isolate the
cavitation from valve surfaces that the cavitation does
impact.

A third method is to change the system in a manner to

3 prevent the causes of Cavitation. If the P2 can be raised
enough so that the vena contracta pressure does not fall
below the vapor pressure, that is the valve is no longer
chocked, then Cavitation will be avoided. P2 can be raised
by moving the valve to a location that has more static head
on the downstream side. Applying an orifice plate or similar
backpressure device can also be raise P2 at the valve; the
downside is the potential for the cavitation to transfer from
43 the valve to orifice plate.
Control Valve
Noise
 CONTROL VALVE NOISE

Introduction
Definition:
dB
 Decibels (dB) are a measure which gives an indication of loudness.

dBA
 The “A” added to the term indicates that the correction accounting for the
response of the human ear has been made(dBA).

 As we analyze noise in the context of pipeline and control valve, we must

consider the origin of the noise.
 Consideration of the source indicates how the noise will propagate.
 A sound level meter is used to determine sound pressure level.

45
 CONTROL VALVE NOISE

Sound Characteristics
Line source
 Reading of line source levels are normally measured 1 meter from the
pipeline surface, at a point 1 meter downstream from the valve outlet.
 Measurements should be made in an unobstructed free field area with
no sound reflecting surface nearby.
 Line source noise level are radiated from the pipeline in the form of an
imaginary cylinder with the pipe center line as the axis.
 As you move away from the pipeline, the sound pressure level(SPL)
decrease inversely to the changes in surface area of the imaginary
cylinder.

46
 CONTROL VALVE NOISE

Sound Characteristics
Line source (cont…)
 The following equation defines the SPL at distances other than 1 meter from the
pipeline surface:
SPL = F + 10Log 1 + r
R+r
where
SPL = the sound pressure level
F = the noise level at 1 meter from the pipe surface
r = the pipe radius in meters based on the pipe outside diameter.
R = the distance in meters from the pipe surface.

 The equation show that the noise level decreases dramatically as the distance from the
pipeline increases.

47
 CONTROL VALVE NOISE

Source of Valve Noise

 The major sources of control valve noise are mechanical vibration noise,
aerodynamic noise and hydrodynamic noise.
Mechanical Vibration Noise
 Generally results from valve plug vibration.
 Vibration of valve components is a result of random pressure fluctuations within
the valve body or impingement upon the movable or flexible parts.
 The most prevalent source of noise is the lateral movement of the valve plug
relative to the guiding surfaces.
 In these situations, the physical damage incurred by the valve plug and
associated guiding surface is generally of more concern than the noise emitted.
 Another source of mechanical vibration noise is resonant vibration which occur
when a valve component resonates at its natural frequency.

48
 CONTROL VALVE NOISE

Source of Valve Noise

Hydrodynamic noise
 Noise resulting from liquid flow- has cavitation as a major source
 This noise is caused by the implosion of vapor bubbles formed in the
cavitation process.
 Hydrodynamic noise sounds like gravel flowing through a pipe.
 Intense cavitation can cause noise levels as high as 115dBA, but such
cavitation would not be tolerated because cavitation damage would
drastically shorten the operating life of the installation.
 Therefore, control valve damage is normally of more concern than the
noise produced in cavitating service.

49
 CONTROL VALVE NOISE

Source of Valve Noise

Aerodynamic noise
 Aerodynamic noise is generated by the turbulence associated with
control of gas, steam or vapors.
 While generally though of as accompanying high capacity, high
pressure systems, damaging noise levels can be produced in a two-
inch line with as little as a 200psi pressure drop.
 Major sources of aerodynamic noise are the stresses or shear forces
present in turbulent flow.
 Some of the sources of turbulence in gas transmission lines are
obstructions in the flow path, rapid expansion and directional changes
in the fluid stream.

50
SIZING AND SELECTION
 SELECTION AND SIZING

Sizing Valves for Liquids

 Following is a step-by-step procedure for liquid flow using the
IEC procedure.
 Each of these steps is important and must be considered
during any valve sizing procedure.

1 Specify the variables required to size the valve as follows:

 Desire design: refer to the appropriate valve flow coefficient table.

Process fluid (water, oil, etc.)
Appropriate service conditions q or w, P1, P2 or P, T1, Gf, Pv, Pc

The ability to recognize which terms are appropriate for specific sizing
procedure can only be acquired through experience with different valve sizing
problems. If any of the above terms appears to be new or unfamiliar,refer to the
Abbreviations and Terminology table for a complete definition.
52
 SELECTION AND SIZING

Sizing Valves for Liquids

2 Determine the equation constant, N.
N is a numerical constant contained in each of the flow equations to
provide a means for using different systems of units
Values for these various constants and their applicable units are given in
Equation Constant table.
Use N1, if sizing the valve for a flow rate in volumetric units (gpm or m 3/h)
Use N6 if sizing the valve for a flow rate in mass units (lb/h or km/h)

3 Determine Fp, the piping geometry factor

Fp is a correction factor that accounts for pressure losses due to piping
fittings such as reducers, elbows or the inlet and outlet connections of
the control valve to be sized.
If such fittings are attached to the valve, the F p factor must be
considered in the sizing procedure.
If, however, no fittings are attached to the valve, F p has a value of 1.0
53 and simply drops out of the sizing equation.
 SELECTION AND SIZING

Sizing Valves for Liquids

4 Determine qmax (the maximum flow rate at given upstream conditions) or
Pmax (the allowable sizing pressure drop)
The maximum or limiting flow rate (qmax), commonly called chocked flow, is
manifested by no additional increase in flow rate with increasing pressure
differential with fixed upstream conditions.
In liquids, choking occurs as a result of vaporization of the liquid when the
static pressure within the valve drops below the vapor pressure of the liquid.
The IEC standard requires the calculation of an allowable sizing pressure
drop (Pmax), to account for the possibility of choked flow conditions within
the valve.
The calculated Pmax value is compared with the actual pressure drop in the
service condition, and the lesser of these two values is used in the sizing
equation.
If it is desired to use Pmax to account for the possibility of chocked flow
conditions, it can be calculated using the procedure for determining q max(the
Maximum Flow Rate) or Pmax (the Allowable Sizing Pressure Drop).
54
 SELECTION AND SIZING

Sizing Valves for Liquids

5 Solve for required Cv, using the appropriate equation:
 For Volumetric flow rate units:

 For mass flow rate units:

 In addition to Cv, two other flow coefficients Kv and Av are used,

particularly outside of North America. The following relationship exist:

55
 SELECTION AND SIZING

Sizing Valves for Liquids

6 Select the valve size using the appropriate flow coefficient table and the
calculated Cv value.

56
 SELECTION AND SIZING

Determining Fp, the Piping

Geometry Factor
 Determine an Fp factor if any fittings such as reducers, elbows or
tees will be directly attached to the inlet and outlet connections of
the control valve that is to be sized.
 When possible, it is recommended that Fp factors be determined
experimentally by using the factors for rotary valves used with
reducers have all been determined in this manner, and their
values are listed in the flow coefficient tables.

57
 SELECTION AND SIZING

Fp values that not listed in

the flow coefficient tables
 Calculate the Fp factor using the following equation:

where

58
 SELECTION AND SIZING

Fp values that not listed in

the flow coefficient tables
(cont…)
In the previous equation, the K term is:

59
 SELECTION AND SIZING

Fp values that not listed in

the flow coefficient tables
(cont…)
K and KB2 are used only when the diameter of the piping
B1

approaching the valve is different from the diameter of the piping leaving
the valve, whereby:

If the inlet and outlet piping are of equal size, then K B1 =KB2, and therefore
they are dropped from the equation

60
 SELECTION AND SIZING

Fp values that not listed in

the flow coefficient tables
(cont…)
 The most commonly used fitting in control valve installations is
the short-length concentric reducer. The equations for this fitting
are as follows:

For an inlet reducer

For an outlet reducer

For valve installed between identical reducers

61
 SELECTION AND SIZING

Determine qmax (the

Maximum Flow Rate)

Values for FF, the liquid critical pressure ratio factor, can be
obtained from figure 5-2, or from the following equation:

62
 SELECTION AND SIZING

Determining ΔPmax (the

Allowable Sizing Pressure
Drop)
ΔPmax can be determined from the following relationships:
For valves installed without fittings

For valves installed with fittings attached

where

63
 SELECTION AND SIZING

Determining ΔPmax (the

Allowable Sizing Pressure
Drop)

 Values of FF, the liquid critical pressure ratio factor can b obtained
from the following equation:

 Values of FL, the recovery factor for valves installed without

fittings attached, can be obtained in the flow coefficient tables.

64
 SELECTION AND SIZING

Comparision of ΔPmax
value
 ΔPmax should be compared with the actual service pressure
differential (ΔPmax =P1 – P2). Therefore, if:
This indicate that chocked flow conditions will
 ΔPmax < ΔP exist under the service conditions specified

Then step 5 of the procedure for Sizing Valves

 ΔPmax < P1 –P2
for Liquids must be modified by replacing the
actual service pressure differential with
appropriate valve sizing equation with the
calculated ΔPmax value.

65
 SELECTION AND SIZING

Representative Sizing Coefficients for

Single-Ported Globe Style Valve Bodies

66
 SELECTION AND SIZING

Representative Sizing Coefficients for

Rotary Shaft Valves

67
 SELECTION AND SIZING

Representative Sizing Coefficients for

Rotary Shaft Valves (cont…..)

68
 SELECTION AND SIZING

Sizing Valves for Gas

 Cg is a gas sizing coefficient
 Because of the problems in using Cv to predict critical flow in both high and low
recovery valves, Fisher Control International, Inc, began testing all valves on air as
well as water.
 From these tests, a gas sizing coefficient. Cg, was defined to relate critical flow to the
absolute inlet pressure.
 Cg can be used to accurately predict the flow at critical conditions for both high and
low recovery valves. Equation below define the equation of Cg:
Qcritical = CgP1
 To make the equation applicable for any gas at any temperature, the same
correction factor can be used that was applied previously to the original Cv equation:
Qcritical = CgP1(520/GT)

69
 SELECTION AND SIZING

Sizing Valves for Gas

Universal Gas Sizing Equation
 This equation is universal in the sense that it accurately predicts the
flow for either high or low recovery valves, for any gas under any
service conditions.
 This equation incorporates both the basic C equation and the C
v g
critical flow equation into a single, dual-coefficient equation.
Additionally, a new factor C1 is introduced:
C1 = Cg/Cv
 C1 is defined as the ratio of the gas sizing coefficient and the liquid
sizing coefficient.

70
 SELECTION AND SIZING

Sizing Valves for Gas

 The C1 equation tells us the valve is high or low recovery or some
place in between.
 A simple illustration will help clarify the relationship between C and the
1
valve recovery characteristics.
High Recovery Valve Low Recovery Valve
Cg = 4680 Cg = 4680
Cv = 254 Cv = 135
C1 = Cg/Cv C1 = Cg/Cv
= 4680/254 = 4680/135
= 18.4 = 34.7

71
 SELECTION AND SIZING

Actuator Selection
 The following parameters must be known at the beginning
of the selection process:
 Power Source Availability
 Fail-Safe Requirements
 Torque or Thrust Requirements
 Control Functions

72
 SELECTION AND SIZING

Actuator Selection
 Power Source Availability
 The power source available at the location of a valve can often point
directly to what type of actuator to choose.
 Typically, valve actuators are powered either by compressed air or by
electricity.
 Some cases water pressure, hydraulic fluid or even pipeline pressure can
be used.
 The selection depends on the ease and cost of furnishing either power
source to the actuator location.
 One must consider the reliability and maintenance requirements of the
power system and their effect on subsequent valve operation.

73
 SELECTION AND SIZING

Actuator Selection
 Fail-Safe Requirements
 The overall reliability of power sources is quite high; however,
many loops demand specific valve action should the power source
ever fail
 Desired action on signal failure may be required for safety reasons
or for protection of equipment such as the boiler or turbine.
 Fail-safe systems store energy, either mechanically in springs or
pneumatically in volume tanks or hydraulic accumulators.
 When power fails, the fail-safe systems are triggered to drive the
valves to the required position and the maintain this position until
resumption of normal operation.
 Actuator designs are available which allow a choice of failure mode
between failing open, failing closed or holding in the last position.

74
 SELECTION AND SIZING

Actuator Selection
 Torque or Thrust Requirements
 An actuator must have sufficient thrust or torque for the
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 limited to
only electric or electrohydraulic actuators with sufficient torque
capability.
 Conversely, electrohydraulic actuators would be a poor choice for
valves with very low thrust requirements.
 The matching of actuator capability with valve body requirement is
best left to the control valve manufacturer as there is considerable
variation In frictional and fluid forces from valve to valve.

75
 SELECTION AND SIZING

Actuator Selection
 Control Functions
 Generally, signal types are grouped as being either two position
(on-off) or analog (throttling).
 On-off actuators are controlled by two-position electric, electro
pneumatic or pneumatic switch.
 Throttling actuators have considerably higher demands put on
them from both a compatibility and performance standpoint.
 The two primary additional requirements for throttling actuators are
compatibility with instrument signal and better static and dynamic
performance to insure loop stability.
 Compatibility with instrument signals is inherent in many actuator
types, or it can be obtained with add-on equipment.
 Stroking speed, vibration and temperature resistance must also be
considered if critical to the application.
 Vibration or mounting position can be a potential problem as the
actuator weight, combined with the weight of the valve may
necessitate bracing.
76
Material Selection
 MATERIAL SELECTION

Mechanical and
physical properties
Yield strength
 The yield strength of a material is the stress required to cause a
permanent deformation of 0.2%. The parameter is utilized heavily in
the design of pressure containing parts, and is one of the basic
parameters used for:
1. Calculation of ANSI B16.34 pressure-temperature ratings
2. Calculation of ASME Boiler and Pressure Vessel Code allowable
stress values.
 Selection of materials which carry loads such as valve stems, cages,
seat rings and bolting.

78
 MATERIAL SELECTION

Mechanical and
physical properties
Hardness
 Hardness is a material’s resistance to penetration of indentation. In
metals, it is usually measured by loading an indenter into the material
and measuring either the depth of penetration or the surface area of
the indentation. The deeper the penetration or the greatest the surface
area of the indentation, the lower the hardness.

79
 MATERIAL SELECTION

Mechanical and
physical properties
Toughness
 Toughness is a material’s resistance to fracture. Toughness has
traditionally been measured using impact tests, such as the Charpy and
Izod tests. In general:
1. A tough material displays a higher percent elongation and/or percent
reduction in area than a brittle material.
2. A tougher material will display a greater difference in yield strength
and ultimate tensile strength than a brittle material.
 Austenitic material (such as 300 series stainless steels and nickel-base
alloys), generally have much greater toughness than ferritic materials
(such as carbon and alloy steels and 400 series stainless steels).

80
 MATERIAL SELECTION

Mechanical and
physical properties
Wear properties
 Wear is a term used in conjunction with a number of mechanisms involving material
removal or damage. The most important specific wear categories encountered in
control valves are sliding wear, erosion and cavitations damage.
1. Sliding wear
 Refer to the damage caused when two mating parts move relative to one
another. The two mechanisms most often encountered in metallic components
of control valves are adhesive wear and oxidation wear.
– Adhesive wear
 Occur when the frictional heat and contact pressure between
asperities on the surface of the two parts are sufficiently high to
cause localized welding.
– Oxidation wear
 Similar to adhesive wear, except that the frictional heat causes

oxidation of the asperities.

81
 MATERIAL SELECTION

Mechanical and
physical properties
2. Erosion
 Erosion is mechanical damage caused by either high-velocity
fluid impingement or impact by abrasive particles in the flow
medium

3. Cavitation damage
 It is caused by the shock waves generated when vapor
bubbles implode during pressure recovery.

 Both erosion and cavitation damage can be minimized by material

selection, although in most cases the use of an appropriate valve
and/or trim style is more effective.

82
 MATERIAL SELECTION

Mechanical and
physical properties
Effects of inlet and differential pressure
 The pressure drop influences material selection for both the body and the
trim components. In flashing application, body erosion can occur in the
cavity below the seat ring. If the pressure drop indicates high-velocity
erosion and/or cavitation may occur, different trim materials will often be
selected than would be used in a non-erosive or non-cavitating situation.

Effects of elevated temperature on yield strength

 Yield strength in metal alloys is a strong function of defects in their
crystalline structure. These defects are formed purposely through heat
treatment, cold working and others to strengthen materials. Elevated
temperatures will effectively lowering the yield strength

83
 MATERIAL SELECTION

Mechanical and
physical properties
Coefficient of thermal expansion.
 When selecting materials for valve that will be used at elevated
temperature, thermal expansion differences must be taken into account.
This is because:
Differential thermal expansion between plugs and cages can
cause binding or excessive looseness at operating temperature
Differential
thermal expansion in a body bonet-cage-seat ring
system can cause loss of gasket load, resulting in leakage.
 Differences in thermal expansion rates must be either eliminated or
accounted for when a valve is to be used at temperature significantly
above ambient.

84
 MATERIAL SELECTION

Material of
construction
 Materials for valve bodies and bonnets must meet a number of
requirements:
1. They must lend themselves to manufacturer by casting to
accommodate the irregular shapes that bodies and bonnets tend to
have.
2. They must be reliable materials; i.e., they must have known
strength properties, and should be produced and sold under
adequate codes and standards to ensure their integrity.
3. They must have adequate mechanical properties while at operating
temperature.
 They must be resistant to corrosion, oxidation and other adverse effects in
the environment where they will be utilized so they will retain their integrity.

85
 MATERIAL SELECTION

Material of
construction
Carbon steel bodies and bonnets
 The standard material for valve bodies and bonnets is ASME SA216 Grade WCC.
This is a carbon steel material which is easily cast, welded and machined. Carbon
steel is used for large majority of power applications due to its low cost and
reliable performance in general applications.

Alloy steel bodies and bonnets

 When higher temperature and/or pressures are involved, alloy steels are often
specified for bodies and bonnets. Most are steels with chromium and/or
molybdenum added to enhance their resistance to tempering and graphitization at
elevated temperature. Among the more popular materials are ASME SA217
grades C5, WC9 and WC6. WC9 (2-1/4% Cr, 1% Mo) is preferred by foundries
and is much easier to work with in manufacturing than C5.

86
 MATERIAL SELECTION

Material of
construction
Stainless steel bodies and bonnets
 The Fisher standard for stainless steel bodies and bonnets is CF8M
(19% Cr, 10% Ni, 2% Mo), which is the cast version of S31600. CF8M
is a relatively low-cost material with good high temperature properties
and excellent resistance to corrosion in a wide variety of environments.

87
 MATERIAL SELECTION

Material of
construction
Trim parts
 Valve trim components have much different material requirements than
valve bodies and bonnets. In general, trim materials must have
excellent resistance to corrosion by the process fluid in order to
maintain adequate flow control and mechanical stability. The following
is a breakdown of the specific properties necessary in the various trim
components:

1. Plugs
2. Cages
3. Seat Rings

88
 MATERIAL SELECTION

Material of
construction
1. Plugs
 Valve plugs provide throttling control and shutoff in globe valves, and
directly impinged by the flow stream. The seating surface of valve plug
must be capable:
a. Withstanding the seat loads required for shutoff.
b. Withstanding the erosive forces generated by fluid jets.
 In cage-guided valves, the plug guide surfaces must be capable:
a. Resist to galling and excessive wear when sliding against the cage
material
b. Withstanding the erosive action caused by clearance flow between
the plug and cage.

89
 MATERIAL SELECTION

Material of
construction
2. Cages
 Valve cages can serve a number of functions in the control valve
depending upon the valve design. The cage must be require to:
a. Withstand to axial compressive loading due to the bonnet bolt and
radial compressive loading
b. Withstand to the radial compressive loading due to the pressure
differential across it.
c. Provide good sliding wear properties in combination with the plug
material.
d. Provide good erosion resistance.

90
 MATERIAL SELECTION

Material of
construction
3. Seat ring
 Seat ring work with the valve plug to provide shutoff. They must be able to withstand:
a. The seat loads required to shutoff as well as the erosive forces caused by the
high fluid velocities.
b. The bending loads imposed on it by the seat ring retainer.

Common trims materials

 The standard valve trim consist of:
 Cage S17400 H900 or CB7Cu-1 H900
 Plug S41600 HT HRC 38 min
 Seat Ring S41600 HT HRC 38 min
 Stem S31600 Condition B

91
 MATERIAL SELECTION

Material of
construction
Alloy 6 corrosion
 Alloy 6 is a cobalt-chromium-tungsten alloy with approximately 1% carbon.
 The material consists of a soft matrix of cobalt-chromium-tungsten solid
solution surrounding a small percentage of hard, brittle chromium carbides.

Bolting
 The most common bolting materials used in Fisher products are ASME
SA193 Grades B7, B8M and B16. The ASME Boiler and Pressure Vessel
Code Section VIII allowable stresses are the main criteria used to
determine bolting materials for most applications.

92
 MATERIAL SELECTION

Use this table as a guide only. A = normally suitable; B = minor to

93 moderate effect, proceed with caution; C = unsatisfactory
94
CODE & STANDARD
 Control Valve Codes
& Standards
PTS 32.36.01.17 Control Valves – Selection, sizing and
specification
ISA 75.05.01 Control Valve Technology
ISA 75.02 Control Valve Capacity
ISA 75.01.01 Flow Equation for Sizing Control Valves
ISA 75.19.01 Hydrostatic Testing of Control Valve
IEC 543-8-3 Control Valve Aerodynamic noise
ISA S75.05 Control Valve Terminology
API RP 553 Refinery Control Valve
ANSI B16.104 Control Valve Seat leakage

96
 References
 Control Valve Handbook by Fisher
 PTS 32.36.01.17
 Control Valve Terminology ANSI/ISA 75.05.01
(2000)
 Masoneilan Control Valve Sizing Handbook

97
 Sample
Datasheet
99
Thermodynamic
Critical Constant
10
 Thank you

10
 Abbreviations and Terminology

10
Equation Constant Table

10
10