INSTRUCALC/PLUS For Windows ™ Version 5.1 Instrument Engineering Software for Control Valves, Flow Elements, Pressure-Relief Devices, Relief Valves, AGA (Orifice Calculations) and FGC (Fixed Geometry Calculations) With auxiliary programs for fluid flow calculations (for Windows 95, 98, 2000, NT, XP) Stanley W. Thrift Gulf Publishing Company Software Division P.O. Box 2608 Houston, Texas 77252-2608 USAINSTRUCALC For Windows Version 5.1 Plus Instrument Engineering Software for Control Valves, ISO Flow Elements, Relief Valves, Pressure-Relief Devices, AGA Orifice Calculations, Flow Meters, and Flow Devices Copyright ©1998 by Gulf Publishing Company. All rights reserved. This program, or parts, thereof, may not be reproduced in any form without the permission of the publisher. This program was complied with Microsoft Visual Basic Version 3.0 Copyright Microsoft Corp., 1994, ‘The material contained herein is supplied without representation or warranty of any kind. The author and publisher assume no liability, consequential or otherwise, of any kind, arising from the use of these programs or any parts thereof. ‘The software heroin may be updated, extended, or otherwise revised by the author and the publisher at their sole discretion, Purchase of this edition, whether in book or disk form, in no way obliges the author and the publisher to provide the purchaser with future editions at a cost below the publisher's suggested retail price. ‘This software is licensed to the user for use on one computer at one time and may not be duplicated (except for the purpose of making backup copies) without permission from the publisher or author.Contents System Requirements ‘Technical Questions About the Author Installation What INSTRUCALC does for You What's New in Version 5.1 Getting Around in This Manual ix ix x x xi xiii xv Instrucale Options Chapter 1: Control Valves (CV) ss ciples, 1 ing and Undersizing, 2 Selecting Body Style, 2 Noise Levels, 3 Formulas Used, 3 Materials of Construction, 3 Sizing the Actuator, 3 Control Valve Rangeability, 4 Considerations for Liquid Flow, 4 Considerations for Gas and Steam Flow, 5 Considerations for Two-Phase Flow, 6 Program Overview, 6 Program Features, 9 Program Menu Options, 10 Program Lead Sheet, 12Liquid Calculations, 12 Liquid Engineering Units, 18 Two-Phase Celoulations, 21 Data Printout, 27 Data Sheet, 28 Gas Calculations, 30 i Gas Engineering Units, 34 Print Summary, 37 Calculation Routines, 39 Liquid Gas Two-Phase Flow Nomenclature Data Files, 44 Import Process Data, 48 Pressure Drop Calculation, 50 Program Pipe Dimensions, 53 Liquid Water Hammer Calculation, 53 Chapter 2: ISO Flow Elements. Program Overview, 58 Sizing Principles, 59 Accuracy, 59 : Program Features, 60 Program Menu Options, 62 Program Lead Sheet, 63 Liquid Calculation. 64 ISO Material Selection, 67 Liquid Engineering Units, 70 Calculation Data Printout, 72 Data Sheet, 74 Orifice Size Gas Calculation, 76 ISO Material Selection, 79 Gas Engineering Units, 82 Print Summary, 84 Calculation Routines, 86 Nomenclature Data Files, 88 Import Process Data, 92 Pipe Inside Diameter, 94 Chapter 3: Relief Valves. Program Overview, 96 Accuracy of the Calculation, 98Sizing Considerations, 99 Types of Valves, 100 Valve Applications, 100 Program Features, 100 Program Menu Options, 103 Program Lead Sheet, 105 ‘Liquid Calculation - Known Flow, 105 Heat Exchanger Entrapped Liguid Calculation, 109 Pipeline Entrapped Liquid Calculation, 113 ‘Heat Exchanger Tube Rupture Calculation, 117 Liquid Engineering Units, 120 Infet and Outlet Pressure Loss Caleulation, 123 Calculation Data Printout, 124 Data Sheet, 126 Gas Calculation Known Flow, 128 ‘Steam Calculation Known Flow, 129 Fire Size Liquid Vaporization, 135 Fire Size Gas Expansion, 139 Gas Engineering Units, 143 Print Summary, 146 Calculation Routines, 148 Liquid Relief Known Flow Gas Relief Known Flow Steam Relief Known Flow Nomenclature Entrapped Liquid - Heat Exchanger Nomenclature Fire Size Liquid Vaporization Fire and Gas Expansion Nomenclature Data Files, 159 Import Process Data, 167 Program Pipe Dimensions, 170 Chapter 4: Relief Devices... Rupture Disks, 171 “Tank Vents, 172 Program Features, 173 Program Menu Options, 174 Program Lead Sheet, 176 Rupture Disk Size Liquid Calculation, 176 Liquid Engineering Units, 179 Inlet and Outlet Pressure Loss Calculation, 180 Calculation Data Printout, 181 Data Sheet,183 Size Gas Calculation, 185‘Tank Vent Gas Calculation, 187 Gas Engineering Units, 190 Print Summary, 192 Calculation Routines, 195 Rupture Disk Liquid Size Nomenclature Tank Vents Nomenclature Data Files, 198 Import Process Data, 201 Program Pipe Dimensions, 203 Chapter 5: Au: fiary Programs. Program Overview, 205 Program Features, 207 Program Menu Options, 209 Program Lead Sheet, 211 Liquid Pipe Loss Calculation, 211 Liquid Data Calculation, 214 ‘Water Hammer ~ Liquid Flow Calculation, 218 Liquid Engineering Units, 221 Calculation Data Printout, 225 Gas Pipe Pressure Loss Calculation, 226 Calculation Data Printout, 225 Gas Data Calculation, 229 Gas Engineering Units, 233 Summary, 236 Auxiliary Programs Routines, 237 Pipe Pressure Loss Calculation Waterhanmmer and Time for Closing Formula Nomenclature Data Files, 239 Import Process Data, 241 Pipe Dimensions, 243 Appendices....sseesees Appendix A: Questions Users Ask Most.Appendix B: Sources .. Control Valves Flow Elements Pitot Tubes Pressure Relief Valves Heat Exchanger, Piping, Entrapped Liquid Tank Vents Rupture Disks Auailiary Programs Instrucale Plus Options ‘AGA Orifice Plates Bonus Section....sersssesesse+ Program Overview, 1 Program Features, 3 AGA Program Menu Options, 4 AGA Program Lead Sheet, 6 AGA Orifice Size Liquid Calculations, 6 AGA Liquid Engineering Units, 10 AGA Material Selection, 12 AGA Calculation Data Printout, 12 AGA Flow Element Data Sheet, 13 AGA Orifice Size Gas Calculation, 15 Print Summary, 18 AGA Gas Engineering Units, 20 AGA Calculation Routines, 23 Nomenclature Data Files, 25 AGA Import Orifice Process Data, 27 AGA Meter Tube Data, 29 FIXED GEOMETRY1, Flow Devices Bonus Section... Program Overview, 31 Program Features, 32 Program Menu Options, 33 FGI Program Lead Sheet, 35 FGI Integral Flow Orifice Assembly Liquid Calculation, 36 FGI Target Meter Liquid Calculation, 40 FGI Elbow Flow Meters Liquid Calculation, 43 FG1 Annubar Flow Element Liquid Caleulation, 47 FG Liquid Engineering Units, 52 FG Material Selection, 54I¢] “eoureiceprsyy odig ZOd 67I ‘EEC sseo0dd Hodwy ZA STI “8[ld BC ZT seangopoUoWioN’ somsodoad pint suonropnoyoo aajatunorf a3po4 suotrepnoye9 suojoue x2}404 suoyppno}vo so pu pinby saopournoy. ECT ‘SUNNOY WORMED ZI 611 ‘SUN Suusomsuq sep 7DI R11 ‘Areamung Od WU SIT TonpmopED seH 92S HPN MOLT OBPOAA TDA ZLT “worEIMa}ED se OzIg }UTIOY ZDd GOT “TOMPIMOTED SoH) OzES HOW XOHOA ZOd LOL ‘PoNS BEC TOM LOL Mow wOHEMITED ZH 901 tonoappg [EHO ZOd ZOl ‘SHEN Supoursug pmbr] ZO 66 “‘voHPINaTeD PIB] 921g II MOL 2p) ZO (96 ‘WoHPINaTeD pINBr] azIg 1ISUMIOY ZO £6 “WoREINOTe) PMY] 21g IN X9HOA OI % ‘SYS pry weorg ZA 16 ‘Suondo nusyy wmsforg ZI 06 ‘sompag uresBarg ZAnAUOID Pox 68 ‘MaIAIOAQ UEIBOIg Noraag sng SIP MOM TAULANOGD CAXLT £8 ‘iajaueiq apisty adi [9d Sg “eyeq ssooo1g Hodwy 191 08 ‘Sofa He TOT aénqvpouawon sonquiasse soyfizo moyf 40} suojatu 1o3s0, sworoumoyf Noga Moy 908 puo prby «ngnuay 91, ‘souTROY WOHENOTED [DT £2 ‘sup SupeouIsuq sep [DI 1 ‘Aroumng yd Td Lg ‘uoneInTED sop IwOUD|A| MOT] TEGNUUY [Dd $9 ‘WoREIMITED SPD SI MOTT MOGI [DI 19 ‘WoRDMOTED sep ORIN PBI, [DA Ls TwonpInopED sep Ajauassy COBUO AO] [SOUT TDI Ss 990Ys BEC 1D pS HOMEY BEC VONEIMI|ED 1DSystem Requirements + Microsoft Windows 3.1, 95, 98, 2000, NT or XP + 8MB of available memory (perferably 16MB) i + 12MB of available free hard disk space + Laser or IBM compatible printer (132 column with compressed print) Graphic display device compatible with Windows 3.1, 95, 98, 2000, NT or XP. (SVGA card recommended) + Any IBM-Compatible machine with an 80386 processor or higher Technical Questions? Write to: - Stanley W. Thrift 5700 Blackwell Side Road Unit 385 Sarina, Ontario N7W 1B7 CANADA sandjthrift@aol.comAbout the Author Stanley W. Thrift, P.E., is a senior member of the Instrument Society of America and past- president of the Sarnia, Ontario, section. He retired from Stearns Catalytic, Ltd. of Samia in October 1986 as an instrumentation engineer. Installation Windows 95/98/2000/NT/XP- From the Windows desktop menu: Left Click on START button and highlight SETTINGS, then left click on CONTROL PANEL and ADD-REMOVE PROGRAMS. Lefi click on Install or ‘Add New Programs as the case may be and continue through the prompts. \ You may also run :\setup.exe from the Start menu where cdrom is your CD dive letter. | Windows NT or Server | (see special instructions in package) For installation or minor technical help, call Gulf Publishing Company at: | (713) 520-4428 or Fax (713) 525-4668 Or log onto our technical support section of our website under "Software" at: www. gulfpub.com For extensive inquiries (calculations, cosmetic, etc.) email the author directly at sandjthrifi@aol.com.What INSTRUCALC does for you INSTRUCALC is a set of engineering programs for calculating control valve, relief valve, pressure-relief devices and various flow element sizes. It also prepares data sheets and instrument summary teports. It is an engineering program rather than an application program inasmuch as it is capable of determining the basic engineering data and requirements for the ‘equipment rather than just using the data to determine the size required. It consists of more than 74 programs divided into four main parts: 1. Control Valves for liquid, gas, steara, and two-phase flow using the ISA formulas. There are programs for calculating C, and analyzing for citation within the valve, critical flow and flashing through the valve, and noise generated by the valve. The Cy is compensated where necessary for these and the piping geometry effects. Messages are displayed to guide you to an optimum valve selection. 2. ISO Flow Elements for flow and restriction orifice plates; flow nozzles and venturies; gas, steam, vapor, and liquids; flange, radius, pipe, and comer taps, Concentric, eccentric, segmental, quadrant edge, and conical plates. Calculates Beta ratio and orifice bore. Calculates flow for a selected bore. Compatible with ISO 5167. 3. Relief Valves for pressure-relief devices, rupture dises, and breather valves. Liquid and gas application. Calculates API or ASME size for known flow, thermal expansion, and external fire. « ‘The external fire program has the option of either the API or the NEPA heat input methods. It also calculates the maximum flowrate for the selected valve and the maximum back pressure, which maintains the required flow as well as the relieving forces, Also included is a set of Auxiliary programs that determines line pressure drops for gas and liquids, calculates compressibility factor, flowing density, vapor pressure and temperature, latent heats at pressure and temperature and physical properties of mixtures, These programs are useful for many other engineering activities such as centrifugal pump line loss calculations and determining pressure available for control valve pressure drop. All device calculation and data sheet information can be saved for later recall. Printouts can be obtained of calculations, data sheets, and instrument summary reports. Any type of engineering unit can be used in the calculations. All conversion factors are contained within the programs tochange from one unit to another and to convert the values of the input data. Data can be imported and exported to and from the programs using ASCII files. Each module of INSTRUCALC allows you to perform these functions: * Make calculations © Prepare data sheets © Prepare summary reports Use the auxiliary programs to size more than 50 different instruments with this easy-to-use and accurate sizing program. The program not only calculates the sizes of control valves, flow elements, and relief devices, but it also produces data sheets for the calculated items. In addition, it Jets you prepare instrument summaries and use the data sheets as a database for generating reports, xiiWhat's new in Instrucalc Version 5.1 * Control Valves now have dynamic valve sizing as an additional option, Besed on changing percentage of flow, the program has added a scrolling system to instantly give variety of data calculations, ‘+ All Flow Elements programs (4) now have an option to calculate the dynamic inlet pressure for increased accuracy. (Never been available) * Forall devices, INSTRUCALC now provides, on an installed basis as compared with the old way of sizing on a shelf basis. This will go a long way to eliminate start-up problems. ‘© Procedures have been added to enable users to easily edit all technical data files. The user can now easily customize the data to his own satisfaction. ‘* Automatically generate the paths that the data files are installed in (This should solve the network problem) ‘+ Inthe Retiof Valve/Steam calculation section, the program used the steam density in error. This is now corrected «The Flow program is applicable for sizes below 2" and beta values outside the limits of 2 to -75. It is for the user to define the limits which are applicable to the users project ASME nozzle losses are now printed. Old Data Files Are Still Compatible All data files from previous versions are compatible. The file data for the changed programs remain as is unless the data are retrieved, recalculated, and saved. If the latter occurs, the data are then converted to the new formula requirements.New Ability to Transfer Data between Files ‘A relational database system is used to store the data. The data for each record are stored in a random access file and the tag numbers and specification data are stored in sequential files. This provides the simplest data recall method with the most efficient use of memory and the fastest access time, The file size is only limited by computer memory.. If the files for each project are kept separate (Le,, different disks or different paths), INSTRUCALC can handle any number of projects and keep all of the data separate and clean without any user input. It is possible to transfer individual data between projects by calling up the data on path, editing the path and saving to a different file. Data can be imported to, and exported from, the programs. ‘We think you will find the INSTRUCALC 5.1 for Windows better than ever. If you have any suggestions, please write us and let us know. We will consider them for a newer version, xivGetting Around in This Manual ‘The word “program” can mean a variety of things. INSTRUCALC is a software program that contains five main programs that include calculation programs, a data sheet program and a summary program. Since this could get confusing, we will use other words to signify certain portions of INSTRUCALC. We will use the word "module" to refer to the five main programs: Control Valves, Auxiliary Programs, ISO Flow Elements, Relief Valves and Relief Devices, The options available in each module include sizing calculations, an option for producing a data. sheet, and an option for generating summaries. These will be referred to as “programs” or “options.” The word “program?” will also be used to refer to INSTRUCALC as a whole, ‘The more than 50 separate sizing programs will be referred to as “routines” (for example, “the Orifice Plate Concentric Flange Tap Sizing Routine”). This should help you differentiate between the parts of INSTRUCALC as we explain them in this manual. ‘This manual is divided into parts. Some parts of INSTRUCALC are common to INSTRUCALC modules and only require one explanation. The sizing programs are each different and so require separate explanations,Chapter 1 CONTROL VALVES Liquid Flow Gas Flow Two-Phase Flow Sizing Principles The control valve is a vital part of most control systems and is the most widely used final control element. To make a proper selection of the size and type can be very simple or very complex and itis not always obvious which it will be. INSTRUCALC assumes the worst and always does a complete engineering analysis of flowingconditions. Because many reliability and control problems can be created by ) installing the wrong valve, the time to avoid that is now, Oversizing and Undersizing ‘There is a tendency to oversize a control valve by taking the largest flow it will have to pass, doubling it to make it operate at the mid-point, and then picking the next available larger size. This can lead to poor control on low flows, with the control valve trying to regulate flow and bouncing on its seat. For a control valve to regulate flow it must cause some pressure loss in the system. For this reason control valves are usually smaller than line size. If the pressure loss is unknown, then use the Line Pressure Drop program in the Auxiliary Routines and draw a system pressure curve. Then extract the pressure drop from this. Refer to the ISA Handbook of Contol Valves for the procedure. It is a rule of thumb that in a properly designed system the control valve size should be one size less than the line size. Spot checks over the years for deviations from this rule have shown that either the line was unintentionally too small or that some special circumstances applied, such as an unavoidable high pressure drop. Also it should be noted that published control-valve capacities are based on line-size valves, and a piping geometry correction factor is required and is provided in the program. ‘The undersized-valve problem is very often caused by increased plant throughput. It can be solved by cracking open the bypass valve, but with variable flowrates this is likely to lead to control problems. A far better solution is to purchase the valve with a larger body and a reduced trim if future increased flowrates can be anticipated. Selecting Body Style Selecting the body style is the most difficult decision to make when specifying a valve. Butterfly and similar high capacity valves offer most C, per dollar, but there are many examples of misapplication that have caused considerable operating problems. For liquids the F, factor is the most useful guide to a logical selection of body style. Cavitation occurs more often than most people expect and should have the most influence in selecting the body style. Cooling water and heat transport fluids at moderate pressure drops have been found to cavitate. If cavitation is ignored, the valve may only control successfully for a short period of time before requiring maintenance or replacement. The F;, factor does not offer a guide for body style selection for gases. Noise may determine the body style because of noise reduction trim, but generally, economics would determine the body selection.Noise Levels Valves in gas and vapor service experiencing large pressure drops can be the noisiest pieces of equipment in a plant (even while performing well and lasting a long time) ‘The noise level may well be unacceptable these days and while it might be possible to reduce the noise with extra insulation, it is far better to recognize the problem now and find the best way of avoiding it by re-engineering the process to reduce the pressure drop or specifying special noise-reducing trim for the valve. Predicting the noise level generated by a control valve is not an exact science. ‘Manufacturers tend to have their own methods for their own products and a standard calculation method has not yet evolved, The program uses the Masoneilan method to determine if there is a noise problem. This may not be accurate for all manufacturers but will be sufficient to make you aware that a problem may exist, so that you can take a remedial course of action immediately. The selected manufacturer will always have the final responsibility to propose equipment that meets al] of the job requirements, so it will ultimately determine the noise value for the proposed valve for the service. The cost of not selecting the right valve for the job can be enormous. Anti-cavitation and low-noise control valves may seem expensive compared to standard valves, but their extra cost is minuscule when compared to an unplanned plant shutdown. A recent example was the failure through erosion of a valve on cooling water service. “The cost of the shutdown which it caused was in excess of $250,000. Had INSTRUCALC been used, it would have predicted that there was an erosion problem but unfortunately it was not checked until after the event. Formulas Used ‘The formulas used in the calculations are those in ANSI/ISA-875.01 and in ISA Handbook for Control Valves by J. W. Hutchison, and the Masoneilan noise prediction formula, Materials of Construction The materials of construction for a control valve are normally selected to meet the temperature and pressure requirements of the process and resist corrosion by the process fluid, Valves in severe service, in addition, may need special materials to resist erosion caused by cavitation or high pressure drops or to ensure a tight shutof?. ‘The program will advise you of these possibilities.Sizing the Actuator The sizing of the actuator is the manufacturer's responsibility. Manufacturers are aware of the out-of-balance forces which are inherent in their designs and are most capable of selecting the best actuator for them. Be sure to specify the control sir pressure range for the actuator sizing. Control Valve Rangeability ‘The rangeability of a control valve is the range of flow conditions over which it can effectively control. This varies with control valve design. ‘Therefore after the first run of the calculation has been made and the body style, trim style, and valve size have been selected, further calculations should be made to ensure that the valve will control over the range of flowrates and pressure drops that will be encountered in service, The Cy calculated is that for the data entered in the calculations. Valve manufacturers list the rangeability of various types of valves, which can be as high as 50:1. This means that if the calculated Cy value for normal flow was 10 and it ‘was expected that the valve would operate half open then a valve with a rated C, of 20 would be selected which would be expected to provide satisfactory control down toa, of 0.4. So, determine the minimum flowrate and the maximum pressure drop that is expected and enter these values. Is the Cy more than the .4 minimum?. Now enter the maximum flowrate and the minimum pressure drop. Is the C, less than the 20 ‘maximum? If there are any other special conditions which must be met, then enter them, Ifthe valve C, range is exceeded, try different valve sizes or different valve body styles until the optimum is reached. Extreme cases may requite more than one valve. For example, you may need a large valve for the high flows and a small one for the low flows, piped in parallel with the small one opening first and becoming wide ‘open at 50% of the control signal, then the large one opening and becoming wide ‘open at 100% of the control signal. By performing these calculations it is possible to select the optimum valve for the service and reduce the possibility of expensive surprises in the future. Considerations for Liquid Flow The internal contours of some valve bodies are such that because of the relationship between velocity and pressure of the flowing fluid, the velocity of the liquid at oneplace in the body may have risen so high that the pressure falls below the vapor pressure of the liquid and pockets of vapor form. Farther along in the valve body the velocity may have decreased enough for the pressure to increase above the liquid vapor pressure. The vapor pockets implode with considerable noise and energy and can be extremely crosive. This is cavitation. It happens more often than most people expect and water is a common culprit. INSTRUCALC always checks for cavitation. To predict cavitation, manufacturers publish a liquid recovery coefficient (Ft) to quantify the characteristic. A low F, number (e.g,, 0.5 for an angle valve) signifies a valve which will cavitate quicker than a valve with a higher F, will (e.g., 0.9 fora globe valve). The lower the F, the greater the tendency to cavitate. The program will calculate a minimum F, from the process conditions and display it at the time the selected valve F_ is to be entered. To avoid cavitation, a valve with a larger F, should be used. If this is not possible, an anti-cavitation trim should be selected. This is a special hard trim designed to keep the implosions away from the softer metal in the body. If this is not possible, a heavier valve body should be considered to avoid premature failure because of metal erosion. Cavitation chokes the valve and reduces its capacity. The program recognizes this condition and compensates for it. When the discharge pressure is lower than the liguid vapor pressure, the liquid will flash into a vapor as it passes through the valve. ‘This is erosive on the valve body but not usually as severely as cavitation. Hardened trim is usually justified. Flashing also affects valve capacity and is allowed for in the calculation. ‘The viscosity of the liquid must be compensated for if the Reynolds number is less than 4000. For this, the valve-style modifier F, is required. Considerations for Gas and Steam Flow ‘The first problem considered in the program is the minimum size valve for sonic velocity. It is vory ofien possible to select a valve having an adequate C, and yet still have sonic velocity at the outlet port. This creates a noise problem which cannot be overcome with a low-decibel trim. If the noise level of the valve is too high (and it most likely will be for al but the smallest valves), a valve larger than the sonic size must be selected to reduce the velocity to below sonic. The final C, has corrections for the gas expansion facior and for piping geometry similar to those for the liquid calculation, ‘The program will calculate the noise level if the optional data is entered, When the noise exceeds the allowable level (usually 80 GBA) and sonic velocity is not the problem, the level can be reduced by selecting aspecial low-noise trim, by installing pipe with thicker wall, or by selecting a special ) valve, Extreme cases may require extra insulation on the pipe and auxiliary devices to take part of the pressure drop, Noise is normally calculated at actual operating conditions. Therefore, run this calculation for the operating flowrate, pressure drop and F,, value for the percentage of valve open. It is not normally necessary to consider worst conditions because they are usually short-term, and noise will usually be tolerated for that time period. Considerations for Two-Phase Flow ‘The program is a combination of the two previous programs and calculates C, based on the effective specific weight of the mixture. Cavitation is checked for and should be handled as for liquid flow. CONTROL VALVES -- Program Overview ‘Version 5 has the capability of sizing the valves on an installed basis. First, the valve is sized for normal static flow as Case 2. Scroll bars in Case 1 increase the flow, the program computes the system flow and calculates the inlet pressure, valve pressure drop and fluid properties. The maximum controllable flow for the selected valve can ‘be easily determined. Similarly scroll bars for Case 3 determine the minimum controllable flow. This solves the mystery of system flow. It clearly shows how the available pressure drop and fluid properties can vary considerably for different rates, of flow and the optimum control valve size and type can be found. Three Programs are provided ~ Liquid Flow Gas Flow Two Phase Flow Each program will calculate and save three different cases of flow conditions and has access to @ sub program which will calculate the available control valve inlet pressures and pressure drops in the piping system for each case. Options for each valve calculation are Calculate Valve Size Calculate Flow Rate Calculate Pressure Drop Each uses the same formulas, rearranged to calculate the unknown variable.Once the pressure and temperature is entered the process data can he automatically entered using the Properties option and selecting the pure or mixture of process fluids from the Fluid Properties data bank. ‘The valve pressure drop can then be calculated using the Calculate System Pressure Drop option, In Version 5.0 an additional input box was added for the control valve elevation, the headings of boxes for input and discharge pipe elevations was changed to inlet pipe start elevation and discharge pipe end elevation. The inputs to these boxes are now the plant elevations. This clarifies and simplifies the data and will require a change to exising data. In this calculation, after entering the source and destination pressure and details and elevations of the piping system, it will calculate the inlet pressure and pressure drop for each case, This data can be transferred to the valve calculation, Back in the calculation, the pressure has most likely changed making it necessary to reelect the process data from the fluid properties option, if the numbers are significantly different, rerun the pressure drop program. The programs have a data base of Typical Valves so that different valve data can be entered into the calculation in order to make the best selection. Try several and calculate until a valve style and size is selected which has the rangeability and does not have cavitation or noise problems. When a final selection is made the exact manufacturers data can be entered for a final calculation, Finally, for liquid valves, take the option for the Minimum Closing Time this is the ‘Water Hammer program to determine if a special closing time is required to avoid water hammer. General If changes are made to data recalled from file, the data will be displayed in the color selected for changed data. This will assist in recognizing the affect the changes make to other calculations and the data sheet. Sizing Philosophy Each manufacturer has his own formula for determining the valve size, the valve noise and the cavitation characteristics, This program uses the ISA sizing formulas, it uses the Masoneilan noise prediction method and incipient cavitation technique. ‘The object of the program is to determine the valve size, the cavitation, flashing and noise problems and prepare a data sheet suitable for bid purposes, Some manufacturers may differ from these conclusions, usually the variations are minor and do not change the size and style. Occasionally the noise and cavitation characteristics will differ so that some engineering judgment will be called for. The failure of a valve because ofcavitation erosion is not unheard of and can be extremely expensive. Sometimes a change in body style is sufficient to eliminate the problem, hardened trim may be required, The cost a this time is usually small.. Some users will not even tolerate incipient cavitation. Be wary of the person trying for a cost advantage, months later when the valve has failed, he will sell you a new valve and you may have a huge bill (Ver 5.0) The typical valve data file is an ASCII text file, three options of files are now available. They can be modified from within the program. The standard file is based on Masoneilan data. [f you prefer another manufacturer then edit the other valve files to whatever you choose. Ifthe manufacturer does not use the incipient cavitation factor (Kc) then enter a zero or leave the box empty. ISA $75 shows data for a typical file. The pressure drop can then be calculated using the Caleulate Pressure Drop option. In Version 5.0 an additional input box was added for the control valve elevation, the headings of boxes for input and discharge pipe elevations was changed to inlet pipe start clevation and discharge pipe end elevation. The inputs to these boxes are now the plant elevations. ‘This clarifies and simplifies the data and will require a change to existing data. In this calculation, after entering the source and destination pressure and details and clevations of the piping system, it will calculate the inlet pressure and pressure drop for each case. This data can be transferred to the valve calculation, Back in the calculation, the pressure has most likely changed making it necessary to reclect the process data from the fluid properties option, if the numbers are significantly different, rerun the pressure drop program, ‘The programs have a data base of Typical Valves so that different valve data can be entered into the calculation in order to make the best selection, Try several and calculate until a valve style and size is selected which has the rangeability and does not have cavitation or noise problems, When a final selection is made, the exact °s 2 final calculation.Finally, for liquid valves, take thé option for the Closing Time. This is the Water Hammer program to determine if a special closing time is required to avoid water hammer CONTROL VALVE - Program Features Perform sizing calculations Calculate either control valve size, flow rate or pressure drop Caloulate piping system pressure drop Calculate the cavitation index Calculate the noise level Supply typical valve data ‘Supply fluid properties at flow conditions Supply steam data Supply pipe sizes ‘Use English or ST engineering units in any mixture ‘Use mass or volume flow units Import process data Print a calculation sheet using the Windows Print Manager Save the data Prepare instrument data sheets WYSIWYG style Initially generate sheets for bid purposes ‘Supply database of standard specification items After vendor selection, revise for permanent records Print a data sheet using the Windows Print Manager Save the data Print a summary of saved records Print all records Print selected records Print only records having requited characteristics This is a program for calculating the size of control valves. ‘The available options are: Liquid flow Gas, steam or vapor flow ‘Two phase flow i© 1 Liquid tow © 2Gas, stoam or vapor flow © 3 Two Phase flow acat EOC | The programs include files of typical valve data, fluid ‘and pipe sizes. They can be edited in the CONTROL VALVE Program Menu Options New calculation Select the required calculation option and the fluid option, then select OK, (or double-click if at least one of the options is already selected). File Default files Recalls file data using the files in the default drives and paths. Other files Recalls file data using the Windows file selection procedure. Data file maintenance Edit Tag Numbers Provides the facility to change the Tag Numbers on file, Or delete records from file Sort data file Rearrange the Tag Numbers in ascending order. Delete the items marked if the edit was saved. 10File default path Data files Path for the default calculation data files User units Path for the default engineering units Headings Path for the printout headings. ‘There are three paths. Ifa Drive and Path different from the Default Path and Drive provided in the initial Set Up Procedure was used, the program will update them to the Drive and Path which was installed, They are saved in sequential file CVWCALC.DRV which resides with the programs. To check or change the paths, either call up the Drive and Path for edit or use a text editor to or change the file contents. Convert V3 file stage 2 Edit Tables (Version 5.1) InstruCale uses Data Tables for Gas, Liquid, Pipe Size and Pipe Modulus properties, these contain data from which exact properties for the flow conditions are calculated, It also has 3 tables for Valve data. These option provides an easy means of customizing them. Items can be added, inserted, deleted and changed. Restrictions are built into the Materials Coefficient of Expansion table on insertion and deletion because the row number is used to save data in the calculations. Each program can edit the tables used in the program. Take note that some, such as the Gas, Liquid and Pipe Size are used by other programs and may include data required only by them. Editing is performed by either clicking the appropriate line in the Grid or entering the line number in Row to Edit and clicking Recall Row. Edit the data and Load Row to the Grid. When a box in the edit line is clicked, information on the data required is displayed above. Save Grid overwrites the old file. A backup file is recommended before you start. The file name is in the heading of the Edit Form and the files are in the program directory. Note that data cannot be edited directly in the grid. Exit Exits from Instrucale to Windows Program Manager. Color Provides color options for InstruCalc displays, using the Windows palette Note that colors for scroll bars, command buttons, disabled text, borders ete., are selected through the Windows Control Panel Print Summary Goes to the print summary program. uCONTROL VALVE Program Lead Sheet ‘The program will only stop at the Lead Sheet if it fails to find the default paths file. To continue, type in the paths and save the file. ‘The Data Files are specific to a project and an instrument type The Units File may be common for all projects and specific for an instrument type The Headings File may be specific for a project and common for all instruments Control Valve Size - Liquid Calculation ‘Three calculation cases are available. The data sheet program uses Case 1 as the maximum flow condition, Case 2 as the normal flow condition and Case 3 as the minimum flow condition. Other than this, cases can be used as required. If the piping configuration and the source and destination pressure are known, the inlet pressure and the pressure drop across the valve can be calculated using the Calculate Pressure Drop option. (Version5 ) Three Typical valve data selections 2for many different valve types are available to download into the calculation. The selections should be edited for the user requirements. Refer to ISA 875 for a guide, Ke is the incipient cavitation factor, If the manufacturer does not provide it, then substitute the FL factor. Process data for many different fluids and mixtures can be downloaded into the calculation. If the valve is controlling a long column of liquid, the minimum valve closing time should be calculated using the closing time option. ‘The data files are in ASCII format and can be customized to the users preference. Units ‘There are four standard unit sets and one user selected set available: Pounds per hour and degrees Fahrenheit Mass Flow - English Un US gallons per minute and degrees Volume Flow - English Units. Fahrenheit Mass Flow - SI Units. Kilograms per second and degrees Centigrade ‘Volume Flow - SI Units. Liters per second and degrees Centigrade User Units, A set of units selected fiom the Liquid Flow Engineering Unit screen Review units To make or change a User Unit set select thi option. The Liquid Flow Engineering Unit screen will be displayed. It shows the available options and the current unit selection. Select the required units and save the User file. Unit Selection Anew calculation defaults to Mass English U ‘The Unit Selection can be made at any time. The input data will be converted to the new units. If a volumetric flow unit set is selected and the specific gravity is not available, the flow is set to zero. Units for any individual input entry can be changed Bby the selecting the Review Units option and choosing from the Liquid Flow Engineering Unit screen. Base Conditions ‘The Base Conditions option will display the current values of base pressure, base temperature and barometric pressure. They should be checked and modified and saved to suit the operating conditions. AGA specifies a base pressure of 14.73 psia for natural gas, 14,696 for liquids with a vapor pressure equal or less than one atmosphere, and a base temperature of 60°. Fluid Properties ‘The Fluid properties option is enabled when the pressure and temperature are entered. The properties required for a calculation are available for pure liquids and mixtures and are provided in the selected units. Caution should be used for mixtures of dissimilar fluids because the mixture law may not apply, Fora pure liquid find the name and select (or double-click) the name, the fluid properties will be entered. For a mixture select the first component. In the componeat box, enter the percentage. Continue until the remaining percentage equals zero, then select calculate in the component box and the program will calculate and enter the mixture values. The fluid properties data base is user updateable. Calculation options are: Valve size Flowrate Pressure drop (ments f@.Volve size | | (Pressure drop Select the calculation option and the necessary input data is enabled. The required variable will be disabled and will receive the calculated value, The Pressure drop and Flowrate options are back calculations with those being the only unknowns in the valve calculation 4Procedure The enabled input boxes define the data required for the calculation. To calculate the valye size Enter the flow rates, the percent of system flow the flow temperature and your best estimate of the inlet pressure, Either Select the option Case 1 properties and select the fluid. Repeat for Case 2 and 3. Or enter the process data Enter then inlet and outlet nominal pipe sizes Select wall and download the wall thicknes: If the pressure drop is unknown then select the option Caleulate pressure drop. ‘The Pressure Drop Calculation Form will be displayed. Enter the piping configuration, the pipe lengths, the pipe material andthe pipe condition. Enter the source pressure and the inlet equipment losses. Enter the outlet equipment losses and the destination pressure, Calculate by clicking Case 1, Case 2 and Case 3 Analyze the data, if the source pressure is a pump the pressure will decrease with an increase of flow. Change and calculate. Click Case 1, 2 and 3 to transfer data to the valve calculation. Click OK to go back to the Valve Calculation, ‘The new inlet pressure and the pressure drop have been added. If the new inlet pressure is significantly different, download the process data again. Select the Typieal Valve Data option and choose the valve type. Click Case 1, Case 2, and Case 3. Editing Data ‘The output data should be examined for adequacy. The flow status should be normal. If not try different valve styles. Hf cavitation persists, specify cavitation trim, If flashing is occurring, hard trim should be specified. ‘The valve size is larger than the line size then the flowrate or line size is incorrect. Will the valve control at the pressure drops and percent of valve C, in the output data?Change data as required and recalculate until a satisfactory valve is found. If you are going out for bids, then this data is adequate. If the manufacturer has been determined, then overwrite the typical data with the manufacturer's data for the selected valve style and recalculate, Dynamic Valve Sizing (Version 5.1) ‘Very often the only process data available is for normal flow. This is adequate for calculating the normal Cv but is not adequate for sizing the maximum and minimum, flows. The pressure loss in a piping system varies with the flowrate and since the object of the control valve is to vary the flowrate, it follows that the control valves inlet pressure and pressure drop and fluid properties will also vary with each change of flow and therefore the required calculated Cv will not be linear with the rate of flow. ‘The manufacturers publish the range of Cv which a valve will successfully control Typically 2% to 100%. But because of the non-linearity of Cv and rate of flow, what range of flows will the combined control valve and piping system allow? (The system rangeability). Static control valve sizing requires that considerable manual data entry to be made to find this out. It is a function of valve selection and pipe size with different process data for each rate of flow In the program, the valve and piping installation can be modeled to dynamically find the system rangeability using the Scroll bars at the top of the Case 1 and Case 3 buttons. This procedure requires the use of the subroutines in the options for Typical valve data, Fluid properties and Cale system pressure drop. First the valve is sized using static conditions for normal flow in Case2. Select the Typical valve data option, Enter the normel pressure and temperature, select the Fluid properties option, select the option to Cale the system pressure drop, enter the system data and the static normal flow conditions in Case2 and calculate. If the source ‘pressure varies with flowrate, as it will for ceatrifugal pumps and compressors, enter the slatic source pressures for the maximum end minimum flowrates. Transfer Case? data and click OK. to go back to the Valve sizing form, If the valve inlet pressure is now different from that calculated in the system pressure drop calculation, re-select the fluid properties and repeat the above procedure. Now, use the scroll bars to change the flowrates. Using the normal conditions as a base, the program will recalculate the equipment losses, recalculate the valve inlet 16pressure and pressure drop, recalculate the fluid properties and recalculate the valve Cv. If values for source pressure at maximum and minimum flowrates were entered in the Pressure drop calculation form, then the source pressure is also recalculated for each flowrate. If the input boxes are left blank, the normal static source pressure is used. While scrolling for the maximum flow, if the calculated Percent of Cv exceeds 100 then a message box will ask ifa larger valve is required. A No answer will complete the calculation showing the Percent of Cv to be greater than 100, a Yes will change the valve size and the show the appropriate value and will require the recalculation of the other two cases. Control valves very often have a rangeabilty of 50:1. If the maximum flow is scrolled up to 100 Percent of valve Cv and the minimum flow is scrolled to 2 Percent of valve Cy, (a range of 50:1), then the system rangeability is the maximum flowrate divided by the minimum flowrate. it is usually a Jot less than the 50:1 for the valve. Is the rangeability adequate? Is a larger pipe required? At 100% of system flow does the valve have a margin of extra capacity? Does it have too much? Is a smaller valve required?. Can the flow be tumed down far enough without the valve bouncing on the seat? Is the pipe too large? Change the data to find the optimum conditions. ‘The number at the bottom of the screen is the number of calculations performed to achieve the results. Filing and Moving On The options in the File menu are: Program menu - Clears the calculation and returns to the main menu. Prepare data sheet - Is enabled after a calculation is made, it displays the screen to prepare a data sheet form for the calculated item. New Record - Clears the screen for a new calculation. ‘Save - Using the default path, it saves a new record ifnot previously saved or saves changes to an existing record, Save New - Using the default path, it saves an existing record as a new record (Used to duplicate similar items. i.e. Recall an existing record. Edit as required and Save New) Save As...~ Uses the Windows file access system, Saves to a file anywhere. Import case data (1, 2 or 3) - Select the units and read Input data supplied in sequential files. File default path - Changes the default paths for the calculation records. The default paths are: ‘The Data Files. (CVWDAT.TAG and CVWDAT.DAT), ”‘The User Unit Files. (CVWDAT.UNS) ) ‘The Printout Headings File (HEADINGS. DAT) Print valye calculation - Is enabled after a calculation is made. It displays the screen to print a calculation. Exit - Leaves the program and retums to the Windows Program Manager “The screen shows the process variables used in a liquid calculation and list the available options. To assure full coverage, (Except Flow Time Base) each has an Other option. This is @ user defined unit. Double click the option and it will display the name and multiplier to convert it to the standard units. The standard unit is always the first item in the list. The screen shows the current selection, Any unit may be selected and will be used in the calculation if OK is selected. To create a User File for the User File Unit option in the calculation, select the desired units and click the save button. A double click on any unit option selects that option and retums to the calculation. Data conversion For all items except flow, the unit change represents only a multiplier to convert the ; input data and the data is always converted, The Flow Quantity option has Mass 18and Volume options. The relationship between mass flow and volume flow is 2 multiplier and the specific gravity of the fluid. If the flow units are changed from mass to volume, or volume fo mass and the specific gravity is not available the flow rate is set to zero. Conversion factors and units are based on API 2564 Definition of units Mass flow units Ib = pounds kg= kilograms tonne = 1000 kg = IMg g= gram UKton =2240 Ib USton = 2000 Ib Other = user defined mass unit Volume flow units : ‘USgal = US gallons litre = litres £13 = cubic feet UKgal = UK gallons m3 = cubic metres bbl = barrels (42 US gallons) m3 = cubic centimetres Other = user defined volumetric unit Flow time base: /s=per second ‘n= per hour Ja= per day Gauge pressure psig = pounds per square inch gauge kPag = kiloPascals gauge atg= atmospheres gauge inches of mercury gauge MPag = megaPascals gatige inH2Og = inches of water gauge mmhgg = millimetres of mercury gauge barg = bars gauge ky/em2g = kilograms per square centimetre gauge Other = user defined gauge pressure unit Pressure drop ‘psi = pounds per square inch kPa= kiloPascals at = atmospheres 19inches of mereury y4 megaPascals inH20 = inches of water millimetres of mercury i ars kg/om2 = kilograms per square centimetre Other = user defined pressure drop unit Absolute pressure : psia = pounds per square inch absolute i KPaa = kiloPascals absolute { atmospheres absolute inches of mercury absolute MPaa=megaPascals absolute inH120a = inches of water absolute mmbga~ millimetres mercury of absolute bara = bars absolute i kg/cm2a = kilograms per square centimetre absolute Other = user defined absolute pressure unit Temperature degF degrees Fahrenheit i dogF = degrees Centigrade i dogR = degrees Rankine dogK = degrees Kelvin ) Other = user defined temperature unit Velocity fs = feet per second m/s ~ metres per second Other = user defined velocity ' Viscosity : cp = centipoises Pascal seconds s = centistokes kPa.s = kiloPascal seconds er defined viscosity unit Pipe and valve diameter : user defined size | Length and elevation : metres Other = user defined length ) 20 |Bulk Modulus & Modulus of elasticity) psi = pounds per square inch kPa = kiloPascals Other = user defined unit Control Valve Size Two-Phase Calculation 10 Volvo size Pressure drop This is a combination of the liquid and gas programs. It is based on the effective specitic weight of the two-phase mixture, Cavitation is handled as a liquid, if there is a large amount of gas then cavitation is unlikely. Three calculation cases are available, the data sheet program uses Case 1 as the maximum flow condition, Case 2 1s the normal flow condition and Case 3 as the minimum flow condition. Other than this, cases can be used as required. If the piping configuration and the source and destination pressure is known, the inlet pressure and the pressure drop across the valve can be calculated using the Calculate pressure drop option. ‘Typical valve data for many different valve types is available to download into the calculation, 2Process data for many different fluids and mixtures can be downloaded into the calculation. If the valve is controlling a long coluran of liquid, the minimum valve closing time should be calculated using the closing time option, ‘The data files arc in ASCII format and can be customized to the user’s preference. Engineering Units “There are four standard unit sets and one user selected set available: i ‘Mass Flow - English Units, Gas and liquid in pounds per hour and degrees Fahrenheit ‘Volume Flow - English Units. Gas in standard cubic feet per minute and degrees Fahrenheit Liquid in US gallons per minute and degrees Fahrenheit Mass Flow - SI Units Gas and liquid in kilograms per second and degrees Centigrade ‘Volume Flow - SI Units. Gas in standard cubic decimeters per second and degrees Centigrade Liquid in litres per second and degrees Centigrade User Units A set of units selected from either the Liquid Flow Engineering Unit or the Flow Engineering Unit screen ‘To make or change a User Unit set select the option Review units. The Liquid or Gas Flow Engineering Unit screen will be displayed. It shows the available options and the current unit selection. Sclect the required units and save the User file, Unit Selection Anew calculation defaults to Mass English Units. ‘The Unit Selection can be made at any time. The input data will be converted to the new units, Ifa volumetric flow unit set is selected and the specific gravity is not availuble the flow is set to zero, Units for any individual input entry can be changed by selecting the Review Units option and choosing from the Liquid or Gas Flow Engineering Unit screen. Base Conditions ‘The Base Conditions option will display the current values of base pressure, base temperature and barometric pressure, ‘They should be checked and modified and saved to suit the operating conditions. AGA specifies a base pressure of 14.73 psia for 2natural gas, 14.696 for liquids with a vapor pressure equall or less than one atmosphere, and a base temperature of 60°. ISO specifies 14.696 psia and 59°, Fluid Properties ‘The Fluid properties option is enabled when the pressure and temperature are entered. ‘The properties required for a calculation are available for either pure liquids or gases and mixtures and are provided in the selected units. Caution should be used for mixtures of dissimilar fluids because the mixture law may not apply. Fora pure liquid or gas find the name and select (or double-click) the name, the fluid properties will be entered. Fora mixture select the first component. In the component box, enter the percentage. Continue until the remaining percentage equals zero, then select calculate in the component box and the program will calculate and enter the mixture values. The fluid properties data base is user updateable Calculation options are: Valve size Pressure drop Select the calculation option and the necessary input data is enabled. The required variable will be disabled and will receive the calculated value, The Pressure drop and Flowrate options are back calculations with those being the only unknowns in the valve calculation Procedure ‘The enabled input boxes define the data required for the calculation. To Calculate the Valve Size Enter the flow rates, the flow temperature and your best estimate of the inlet pressure, Select the option Case 1 properties and select the fluid, Repeat for Case 2 and Case 3. ‘The program expects that Case | will be the maximum flow, Case 2 the average and Case 3 the minimum. The standard typical file supplies valve data for 100% 50% and 10% of valve capacity The process data are calculated from published formulae, it is sufficiently accurate for most calculations, If you have more accurate data it can be manually entered The percent of system flow input enables the valve size and valve rated to be calculated for the typical valve data in each case Enter then inlet and outlet nominal pipe sizes 2BSelect wall and download the wall thickness. Ifthe pressure drop is unknown then select the option Calculate pressure drop. ‘The Pressure Drop Calculation Form will be displayed. Enter the piping configuration, the pipe lengths, the pipe material and the pipe condition. Enter the source pressure and the inlet equipment losses. Enter the outlet equipment losses and the destination pressure. Calculate by clicking Case 1, Case 2 and Case 3 Analyze the data, if the source pressure is a centrifugal pump, the pressure will decrease with an inerease of flow. Change and calculate. The input boxes for minimum and maximum flow source pressures are only used for the dynamic sizing described below. Click Case 1,2 and 3 to transfer data to the valve calculation. Click OK to go back to the Valve Calculation, ‘The new inlet pressure and the pressure drop have been added. If the new inlet pressure is significantly different, download the process data again Select the Typical Valve Data option and choose the valve type. IF Ke (the incipient cavitation index) is not available then leave the box blank. Click Case 1, Case 2, and Case 3 ‘The number appearing in the bottom right hand corner is the number of calculations {ie. the square root of (+X) is 3) and logic operations (IF, And, OR), performed. Editing Data If changes are made to data recalled from file, the data will be displayed in the color selected for changed data, This will assist in recognizing the affect the changes make to other calculations and the data sheet. If the calculated percent of valve is more than the percent of system flow an error message will ask if you wish to increase the valve size, this will enable you to optimize the valve size. Once a value for the valve size is available, the program will only overwrite it via the error message,. If you wish to start over, then zero out the valve size and recalculate, or just overwrite your desired valve and rated sizes and recalculate. The relationship between the percent of system flow and the percent of valve capacity is an indication of the valve rangeability, the excess capacity of the valve and the normal operating capacity of the valve. It should be noted that the typical valve data values for are based on the system percentage flow whereas they are really dependent on the percentage of valve opening. This is normally insignificant but can be overwritten if desired. ‘The output data should be examined for adequacy. ‘The flow status should be normal. Ifnot try different valve styles. If cavitation persists, specify cavitation trim. 24‘The valve size is larger than the line size then the flowrate or line size is incorrect. Will the valve control at the pressure drops and percent of valve Cv in the output data? Is the rangeability adequate? At 100% of system flow does the valve have a margin of extra capacity? Does it have too much?. Is a smaller valve required Change data as required and recalculate until a satisfactory valve is found. If you are going out for bids, then this data is adequate. If the manufacturer has beea determined, then overwrite the typical data with the manufacturers data for the selected valve style and recalculate. Dynamic Valve Sizing (Version 5.1) ‘Very often the only process data available is for normal flow. This is adequate for calculating the normal Cv but is not adequate for sizing the maximum and minimum flows. ‘The pressure loss in a piping system varies with the flowrate and since the object of the control valve is to vary the flowrate, it follows that the control valves inlet pressure and pressure drop and fluid properties will also vary with each change of flow and therefore the required calculated Cv will not be linear with the rate of flow. ‘The manufacturers publish the range of Cy which a valve will successfully control. Typically 2% to 100%. But because of the non-linearity of Cy and rate of flow, what range of flows will the combined control valve and piping system allow? (The system rangeability). Static control valve sizing requires that considerable manuel data entry to be made to find this out, It is a function of valve selection and pipe size with different process data for each rate of flow In the program, the valve and piping installation can be modeled to dynamically find the system rangeability using the Scroll bars at the top of the Case 1 and Case 3 buttons. This procedure requires the use of the subroutines in the options for Typical valve data, Fluid properties and Cale system pressure drop. First the valve is sized using static conditions for normal flow in Case2. Select the valve data option, Enter the normal pressure and temperature, select the Fluid s option, select the option to Cale the system pressure drop, enter the system data and the static normal flow conditions in Case? and calculate. If the source pressure varies with flowrate, as it will for centrifugal pumps and compressors, enter the static source pressures for the maximurn and minimum flowrates. Transfer Case2 data and click OK. to go back to the Valve sizing form. If the valve inlet pressure is 25now different from that calculated in the system pressure drop calculation, re-select the fluid properties and repeat the above procedure. ‘Now, use the seroll bars to change the flowrates. Using the normal conditions as 4 ‘ase, the program will recalculate the equipment losses, recalculate the valve inlet pressure and pressure drop, recalculate the fluid properties and recalculate the valve Cy. If values for source pressure af maximum and minimum flowrates were entered in the Pressure drop calculation form, then the source pressure is also recalculated for each flowrate. If the input boxes are left blank, the normal static source pressure is used. While scrolling for the maximum flow, if the calculated Percent of Cv exceeds 100 then a message box will ask if a larger valve is required. A No answer will complete the calculation showing the Percent of Cy to be greater than 100, a Yes will change the valve size and the show the appropriate value and will require the recalculation of the other two cases. Control valves very often have a rangeabilty of 50:1. If the maximum flow is scrolled up to 100 Percent of valve Cv and the minimum flow is scrolled to 2 Percent of valve Cy, (a range of 50:1), then the system rangeability is the maximum flowrate divided hy the minimum flowrate, It is usually a lot less than the 50:1 for the valve. Is the rangeability adequate? Is a larger pipe required? At 100% of system flow does the valve have a margin of extra capacity? Does it have too much? Is a smaller valve required?. Can the flow be tumed down far enough without the valve bouncing on the seat? Is the pipe too large? Change the data to find the optimum conditions. ‘The number at the bottom of the screen is the number of calculations performed to achieve the results Filing and Moving On The options in the File menu are: Program menu - Clears the calculation and returns to the main menu. Prepare data sheet -Is enabled after a calculation is made, it displays the screen fo prepare a data sheet form for the calculated item. New record - Clears the screen for a new calculation. Save Using the default path, it saves a new record if not previously saved or saves changes to an existing record. Save New - Using the default path, it saves an existing record as anew record (used to duplicate similar items, ic. recall an existing record, Edit as required and Save New). Save As....~ Uses the Windows file access system. Saves to a file anywhere. Import case data (1, 2 or 3) - Select the units and read Input data supplied in sequential files. 26File default path - Changes the default paths for the calculation records. ‘The default paths are The Data Files. (CVWDAT.TAG and CVWDAT.DAT). ‘The User Unit Files. (CVWDAT.UNS) The Printout Headings File (HEADINGS.DAT) Print valve calculation - Is enabled after a calculation is made. It displays the screen to print a calculation, Exit - Leaves the program end retums to the Windows Program Manager. CONTROL VALVE Calculation Data Printout This program will print the input and output calculation date and one associated comment. The comment is included in the data sheet for reference purposes. Italso creates the defeult printout headings. The headings are printed at the top of all. printouts. They are saved in the HEADINGS.DAT file. This is the third default path. Ifall programs are set to the same path, this becomes the default headings for all program printouts, ce [Octagon Engineering Corporation fs Sa Plant Conversion iE [2000 Update festa [Masoneilon or equal (10000 E instucale 5 Le 21Save Headings. Saves the headings Cancel. Returns to the calculation form without printing OK. Prints the headings and calculation using the Windows Print Manager, then returns to the calculation form CONTROL VALVE Data Sheet ‘sig Fagineing Coonan (Cont Valve - Lieu fw Spee. Projo 2314 Plant Conversion Req 2001 Update By VaneBdy [Date Sroidae Resa ae ca ‘ey sare peer “Baur [DT Nentestss Ie | Teg ostnnae rset a = a Sa Tas [iba eas ae we ee ea sear Poe ems ae aaa aa oh ee a =a aig ae ee Se ot — Bessa ae ae ear hheearee — bm Tat 28The first use of the data sheet is to obtein competitive bids. It should initially erophasize the engineering requirements and be fairly general regarding the details. When a vendor is selected it should be updated to the exact details so that the data sheet is a record of the instrument purchased. ‘The relevant data from the calculation is automatically displayed. Minor editing, such as rounding can be performed. Major editing should be done in the calculation routine in order to preserve the integrity of the calculation, A.user defined database is available to enter data for those inputs which have a limited number of options. To activate this, double click the input box, the data on file is displayed. Double click the required option and the data is transferred to the data sheet form. ‘The data base should be customized for the project requirements. To edit the data; click the selected item. Edit the data in the active top line, select Replace, continue with the edit and Save on completion. The Input data menu option has option to center either the first or the second item in the list for all items. If the data base is constructed so that the first item is the first standard selection and the second item is the second standard selection then two standard data sheets are available for a single keystroke. This feature only enters data into empty input boxes. ‘Some input boxes require unique data which is typed in. Space is provided to enter information for non standard options. Enter the title and data, it will be saved with. the other data. Three lines of notes of special instructions are available at the bottom ofthe data sheet. The input data is limited to 25 characters and 60 characters for each of the notes. Data Sheet File options Print data sheet - Prints the data sheet using the Windows Print Manager. Refer to Windows Help Go to calculation - Returns to the calculation form using the same record Update headings - Ovecwrites the headings with the current default set 29Control Valve Size - Gas Calculation eaters ‘Three calculation cases are available, the data sheet program uses Case 1 as the maximum flew condition, Case 2 as the normal flow condition and Case 3 as the minimum flow condition. Other than this, cases can be used as required. If the piping configuration and the source and destination pressure is known, the inlet pressure and the pressure drop across the valve can be calculated using the Caleulate pressure drop option. ‘Typical valve data for many different valve types is available to download into the calculation. Process data for many different fluids and mixtures can be downloaded into the calculation, ‘The data files are in ASCII format and can be customized to the users preference. 30 —)Engineering Units ‘There are four standard unit sets and one user selected set available: ‘Mass Flow - English Units. Pounds per hour and degrees Fahreniheit ‘Volume Flow - English Units. Standard oubic feet per minute and degrees Fahrenheit Mass Flow - ST Units. Kilograms per second and degrees Centigrade ‘Volume Flow - SI Units. Standard cubic decimeters per second and degrees Centigrade User Units. A set of units selected from the Gas Flow Engineering Unit screen To make or change a User Unit set select the option Review units. The Gas Flow Engineering Unit screen will be displayed. It shows the available options and the current unit selection. Select the required units and save the User file. Unit Selection A new calculation defaults to Mass English Units, Tho Unit Selection can be made at any time. The input data will be converted to the new units. If a volumetric flow unit set is selected and the specific gravity is not available the flow is set to zero, Units for any individual input entry can be changed by selecting the Review Units option and choosing from the Gas Flow Engineering Unit screen. Base Conditions The Base Conditions option will display the current values of base pressure, base temperature and barometric pressure. They should be checked and modified and saved to suit the operating conditions. AGA specifies a base pressure of 14.73 psia for natural gas, 14.696 for liquids with a vapor pressure equal or less than one atmosphere, and a base temperature of 60°, Fluid Properties The Fluid properties option is enabled when the pressure and temperature are entered, The properties required for a calculation are available for pure gases and 31mixtures and are provided in the selected units. Caution should be used for mixtures of dissimilar fluids because the mixture law may not apply. For a pure gas find the name and select (or double-click) the name, the uid properties will be entered For a mixture select the first component. In the component box, enter the percentage, Continue until the remaining percentage equals zero, then select calculate in the ‘component box and the program will calculate and enter the mixture values. The fluid properties database is user updateable. Calculation options are: Valve size Flowrate Pressure drop fete nntnmel santas ‘Valve size Select the calculation option and the necessary input data is enabled. The required variable will be disabled and will reocive the calculated value. The Pressure drop and Flowrate options are back calculations with those being the only unknowns in the valve calculation. Procedure ‘The enabled input boxes define the data required for the calculation, To calculate the valve size Enter the flow rates, the percent of system flow the flow temperature and your best estimate of the inlet pressure. Either Select the option Case 1 properties and select the fluid. Repeat for Case 2 and 3, Or enter the process data Enter the inlet and outlet nominal pipe sizes. Select wall and download the wall thickness. Ifthe pressure drop is unknown then select the option Caleulate pressure drop. ‘The Pressure Drop Calculation Form will be displayed. Enter the piping configuration, the pipe lengths, the pipe material and the pipe condition, 2Enter the source pressure and the inlet equipment losses. Enter the outlet equipment losses and the destination pressure Calculate by clicking Case 1, Case 2 and Case 3. Analyze the data, if the source pressure is a pump the pressure will decrease ‘with an increase of flow. Change and calculate. Click Case 1, 2 and 3 to transfer data to the valve calculation, Click OK to go back to the Valve Calculation, ‘The new inlet pressure and the pressure drop have been added, If the new inlet pressure is significantly different, download the process data again, Then nan the pressure drop calculation again. Select the Typical Valve Data option and choose the valve type. Click Case 1, Case 2, and Case 3. Editing Data ‘The output data should be examined for adequacy. ‘The flow status should be normal. If not, try different valve styles. Noise is only a problem at normal flows. If the noise level is too high download a low db valve. If itis still too high, other devices may be necessary to reduce the pressure drop. If the valve size is larger than the line size, the flowrate or line size is incotrect. Will the valve control at the pressure drops and percent of valve C, in the output data? Change data as required and recalculate until a satisfactory valve is found. If you are going out for bids, then this data is adequate. If the manufacturer has been determined, overwrite the typical data with the manufucturer’s data for the selected valve style and recalculate. Filing and Moving On ‘The options in the File menu are: Program menu - Clears the calculation and retums to the main menu. Prepare data sheet - Is enabled after a calculation is made, it displays the screen to prepare a data sheet form for the calculated item, ‘New record - Clears the screen for a new calculation. ‘Save - Using the default path, it saves a new record if not previously saved or saves changes to an existing record. 33Save New - Using the default path, it saves an existing record as a new record (used to duplicate similar items, ic. recall an existing | record. Edit as required and Save New) Save As. - Uses the Windows file access system. Saves to a file anywhere. Import case data (1, 2, or 3) - Select the units and read Input data supplied in sequential files. File default path - Changes the default paths for the calculation records i “The default paths are: The Data Files. (CVWDAT.TAG and CVWDATDAT). i ‘The User Unit Files. (CVWDAT.UNS) \ ‘The Printout Headings File (HEADINGS.DAT) i Print valve calculation - Is enabled after a calculation is made. It displays : the screen fo print a calculation. Exit - Leaves the program and returns to the Windows Program ‘Manager CONTROL VALVE Gas Engineering Units “The soreen shows the process variables used in a liquid calculation and lists the available options, To assure full coverage, each (except Flow Time Base) has an “Other” option. This is a user defined unit. Double click the option and it will \ 34display the name and multiplier to convert it to the standard units. ‘The standard unit is always the first item in the list. The screen shows the current selection, Any unit may be selected and will be used in the calculation if OK is selected. To create a User File for the User File Unit option in the calculation, select the desired units and click the save button, A double click on any unit option selects that option and returns to the calculation. Data Conversion For all items except flow, the unit change represents only a multiplier to convert the input data and the data is always converted. The Flow Quantity option has Mass and Volume options. The relationship between mass flow and volume flow is a multiplier and the molecular weight of the gas conversion can only be made when the molecular weight has been entered. Definition of units Mass flow units : ib = pounds kg = kilograms tonne = 1000 kg= IMg g= gram UKton = 2240 Ib USton = 2000 Ib Other = user defined mass unit Volume flow units : sfi3 = standard cubic feet sdm3 = standard cubic decimetres sm3 = standard cubic metres Msft3 = million standard cubic feet Other = user defined volume unit Time base {s= per second /m = per minute fh = per hour [d= per day Gauge pressure psig = pounds per square inch gauge kPag = kiloPascals gauge atg = atmospheres gaugeinhgg~ inches of meroury gauge ‘Pag = megaPascals gauge inH2Og = inches of water gauge mmbhgg = millimetres of mercury gauge barg = bars gauge kg/em2g = kilograms per square centimetre gauge Other = user defined gauge pressure unit Pressure drop : psi = pounds per square inch kPa = kiloPascals MPa = megaPascals inH120 = inches of water mmbg = millimetres of mercury bar = bars kg/cm? = kilograms per square centimetre Other = user defined pressure drop unit Deasity Tb/fi3 = pounds per cubic foot kgim3 = kilograms per cubic metre g/cm = grams per cubic centimetre Ibyin3 = pounds per cubic inch Other = user defined density unit Absolute pressure : psia = pounds per square inch absolute KPaa = kiloPascals absolute ata = atmospheres absolute inhga = inches of mercury absolute MPaa= megaPascals absolute inF120a = inches of water absolute mmiga = millimetres of mercury absolute bara = bats absolute kg/em2a = kilograms pet square centimetre absolute Other = user defined absolute pressure unit Temperature degF = degrees Fahrenheit deg = degrees Centigrade degR = degrees Rankine degX = degrees Kelvin Other = user defined temperature unit Velocity Vs = feet per second mis = metres per second Other = user defined velocity 36Viscosity : ep = centipoises Pass = Pascal seconds cs = centistokes kPa.s=kiloPascal seconds Other = user defined viscosity unit Pipe and valve diameter : in = inches mm = millimetres em = centimetres E ft= feet m= metres Other = user defined size Length and elevation ft= feet m = metres Other = user defined length PRINT (CONTROL VALVE) Summary The program will provide a printout summary of data sheet records on file, It is accessed from the main Control Valve program options screen. It can provide a printout of either: All fields Selected fields Fields equal to Fields not equal to Fields equal to or less than Fields equal to or greater than Fields less than Fields more than Procedure for a new Summary Select Options Clear cheeks Clears all checks on the form Clear Other Data Clears all other data on the form Make new field selections Each ficld has four boxes A check box to select the fieldA box to specify the field width A box to enter data to compare ‘A box to specify the compare method (Double click for data) Select data relationship And or or Click Select Printer to print using Windows Print Manager File Options Go to Program Menu Form Returns to program menu for further work on this module Save print options Saves a standard printout Exit Retums to the Windows Program Manager Procedure for a standard printout Select Options Recall saved options Print Procedure to print all fields Select Options Check all Print Other Options Select fon Windows font selection procedure Select Printer Windows Print Manager 38Control Valve Calculation Routines Liquid 1 Calculate the vena-contracta pressure drop - Py =P,- (0 $6028, 2 Celouat the esta op Pos = Five 8 Calauat preliminary valve siting coetent- pW 500,/APG, 4, Calculate Reynolds Number- 346F,W [ F2C} +t I* 00d? Hop yFLCy 5. Calculate Reynolds Number Factor - cy F, =1044— osse{ &2) Cyr Where - 4088s 1 Wu. Cy =| Hor _ ites (tts end- 0.8687 / 2, 9.1057 aoe) Fe" (eso? 6. Caloulate the pressure recovery and piping geometry factors ay‘ a)‘ e (§) Koer(Z) «-09(-§) (Kut KooFEC2 | T* a (Contacte! 890d" 7 Calculate the final valve size - Turbulent flow - PreliminaryCy oy =e ? Fir = or Transitional tlw - ¢, - Preliminaryc, RT or Laminar flow cor Choked or flashing flow - Ww. Cc, =—_————— “ 800F 5 VAP our Gr 8 Calculate the noise level SL=10LogC, +20LogAP ~ 30Log(t)+5 For incipient cavitation add -- AP Papas F2-K, 5 oP, +1-Pyan) For full cavitation subtract from incipient cavitation — SLOG AP +1- APoa) cas 1 Calculate the pressure drop ratio factors, kK A-* 1 e414 2 Calculate the minimum size for sonic velocity w. ff, yn = 00484157 Gs inches 3 Calculate the preliminary valve size w gfe eee 633K Pin 4 Caloulate the piping geometry factor 4 4 d a -|— Ky, =1-|— G) +(e) os F -(& Kp +Ker~Ker)Or 4 : ‘eg0d" 5 Calculate the pressure drop ratio factor X [eli +Ke)OF r F?| 10000" {6 Calaulate the expansion factor vat SFX 7 Calculate the final size Fina, = PreliminanyCy FY 8 Calculate the valve sound pressure level SL,= toled 28¢,FPP.D™ Ks, Xp = 409 Calculate the outlet noise SL, = 10Log(0.18P?d’D2M,T,) + SLe 40.it SL,-SL, 27 then SL=SL, Else SL=SL,+SL, ‘Two Phase Flow 1 Caloulate the vena-contracta pressure drop f P, 0.96 - 0.28, Fae [Puss s a 2 Caloulate the critical drop 5 Pont = FP ye 3 Calculate the specific volumes of the gas and liquid 1 0.016033 eae ¥=—— tn G, -4.Celculate the volume fraction and the weight fraction of the gas v, =—wavs t, oO WaVe tWVe a wy 5 Calculate the pressure drop ratio factors AP Xe OF aust z 14 6 Calculate the expansion factor 8 Calculate the preliminary valve size, o, =e) Py 8S KP ‘9 Calculate the piping geometry factor ay _, (ay “(e) Ka =-[5) Bice Key 2 \o5 p= (CS , 10 Calculate the final size 41PreliminaryC y Nomenclature Cy Vaive sizing coefficient d Nominal vaive size D, + Inside diameter of inlet piping D2 Inside diameter of outlet piping ‘Ys Fluid density at operating temp and pressure Fa Vatee style modifier k Ratio of specific heats Fe Ratio of specific heats factor FL ated pressure recovery factor Combined liquid pressure recovery factor Fe piping geometry factor Reynolds number factor G, specific gravity at flow temperature M Molecular weight Mach number at fow conditions Pi Upstream absolute pressure P. Downstream absolute pressure Pe critical pressure Puse vapor pressure AP Valve pressure drop SL Sound pressure level Ske as property factor t Pipe wall thickness Ti Absolute upstream temperature Rev Reynolds number Ye Effective two phase specific volume Yi Specific volume of liquid y, © Specific volume of gas ‘2 Volume fraction of gas W Tolal rate of flow Wi Rate of liquid ow dimensionless inches inches Inches pounds per cubie foot, dimensionless dimensionless dimensionless dimensionless dimensionless dimensionless dimensionless dimensioniess psla psia psia psia psi OBA dBA Inches degR jensionless #3 ft9fb dimensionless bh tbh )Ws Rate of gas flow on X+ pressure drop ratio dimensionless %r Rated pressure drop ratio factor dimensionless Xe Value of XT for valve/reducer assembly dimensionless Y Expansion factor dimensioniess N Acoustic efficiency dimensionless References Contrat Valve Sizing Equations ANSISA $76.01 Masoneilan Noise Contro! Manual Masoneilan - Dresser ISA Handbook of Control Valves. J. W. Hutchison aCONTROL VALVE Data Files : INSTRUCALC V5 Random access file specification for control valves CVWDAT Dat. Tag Numbers are stored in the sequential file CVWDAT.TAG. Its number in the file is the record number in the random access file. Type FileData ProgNums As Integer 2 bytes: i PipeConds As Integer 2bytes | PipeMatls As Integer 2 bytes | ValveTypes As String * 25 25 bytes. GasBasiss As String * 3 3 bytes LigBasiss As String * 3 3 bytes. FS(0 To 27) As Single 112 bytes.Units conversion factor GS0(0 To 27) As Single 112 bytes. GS1(0To 27) As Single 12 bytes, GS2(0 To 27) As Single 112 bytes, UnS(0 To 27) As Siring * 8 224 bytes.Unit Name PDCO(I To 6) As Single 24 bytes PDC1( To 6) As Single 24 bytes. | PDC2(I To 6) As Single 24 bytes. PDSs(1 To 6) As Single 24 bytes. ) PDIs(1 To 14) As Integer 28 bytes. WHs(0 To 11) As Single 48 bytes Data sheet info SDS(1 To 7) As Single 28 bytes Spec inputs INorm dbA, 2Max Flow,3Max inlet press,4max SO press, Smax temp,6Maxliqflo(2Ph) Cales(1 To 4) As String * 15 60 bytes.Cale array selections AraS(1 To 34) As String * 25 850 bytes. Data sheet array selections Services(1 To 5) As String * 25 125 bytes.Data sheet service, line num, fluid Notess(1 To 3) As String * 60 180 bytes.Data sheet notes Sheots(1 To 7) As String * 1070 bytes. Data sheet num, spec,tev,date,teq,by,appr End Type Record len=2194 PipeConds See pressure drop program PipeMatls Gitte ValveTypes Valve design typeGasBasiss "Mas" for gas mass calc, "Vol" for volume LigBasiss "Mas" for liquid mass calo, "Vol" for volume If ProgNum = 1 Then Program = "Control Valve - Liquid flow" GSx(1) = Flow FS(1) UaS(1) GSx(2) = Flow temperature UnS(2) GSx(3) = Inlet pressure FSG) UnS@) GSx(4) = Valve pressure drop FS(4)_ UnS(4) GSx(6) = Specific gravity at FTP GSx(7) = Viscosity at FTP FS(7) UnS(7) GSx(8) = Vapor pressure FS(8)_ UnS(8) GSx(26) = Critical pressure FS(26) UnS(26) GSx(14) = FL Coefficient at % flow GSx(15) = Calculated CV GSx(19) = Percent Flow GS0(16) = Valve size FS(16) UnS(16) GS1(16) = Valve rated Cv GS2(16) = Valve Fd GS0(17) = Valve rated FL. GS1(17) = Valve rated XT GS2(17) = Valve ratedKC GS0(18) = Inlet pipe size FS(17) UnS(18) GS1(18) = Outlet pipe size FS(17) UnS(18) GS2(18) = Outlet pipe wall thickness FS(18) UnS(18) GS80(21) = Base temperature UnS(2i) GS0(22) = Base pressure FS(22) UnS(22) ‘GS0(23) = Barometric pressure FS(23) UnS(23) SD(1) = Normal dbA ‘SD(6) = Maximum liquid flow FS(1) UnS(1) Maximum inlet pressure FS(3)_ UnS(3) Maximum shut off differential pressure FS(4) UnS(4) Maximum temperature UnS(2) Water hammer sub program WHS(1) = Maximum flow FS(1) UnS(1) WHS(2) = Flow temperature Uns(2) WHS(3) = Operating pressure FS@3) UnS@) WHS(4) = Maximum allowable pressure FS) UnSG) WAHS(5) = Specific gravity at FTP WHS(6) = Liquid bulk modulus FS(27) UnS(27) WHS(7) = Line elastic modulus FS(27) UnS(27) WHS(8) = Line length FS(25) UnS(25) 45WHS(9) = Pipe inside diameter FS(18) UnS(18) WHS(10) = Pipe wall thickness FS(18) UnS(18) ‘WHS(11) = Selected time secs SDS(7) = Minimum time secs If ProgNum =2 Then Program = "Control Valve - Gas, Steam and Vapor flow” GSx(0) = Flow FS(0) UaS(0) Flow temperature UnS(2) nlet pressure FS(@) UnS(3) Valve pressure drop FS(4) UnS(4) Molecular weight Compressibility factor FS(9) UnS() GSx(10) = Ratio of specific heats GSx(L1) = Critical pressure FS(11) UnS(11) GSx(12) = Critical temperature UnS(12) GSx(14) = FL Coefficient at % flow GSx(15) = Calculated CV GSx(19) = Percent Flow GSx(27) = Acoustic efficiency GS0(13) = Gas property dbA : GS1(13) = Valve rated efficiency ) GS0(16) = Valve size FS(16) UnS(16) GS1(16) = Valve rated Cv GSO(17) = Valve rated FL GSI(17) = Valve rated XT GS0(18) = Inlet pipe size FS(17) UnS(18) GS1(18) = Outlet pipe size FS(17) UnS(18) GS2(18) = Outlet pipe wall thickness FS(18) UnS(18) GS0(21) = Base temperature UnS(21) GS0(22) = Base pressure FS(22) UnS 22) GS0(23) = Barometric pressure FS(23) UnS(23) SD(1) = Normal dbA ‘SD(2) = Maximum gas flow FS(Q) UnS(0) ‘SDG) = Maximum inlet pressure FSG) UnSG) SD(4) = Maximum shut off differential pressure FS(4)__ UnS(4) SD(5) = Maximum temperature UnS(2) If ProgNum = 3 Then Program = “Control Valve - Two Phase flow" GSx(0) ~ Gas flow FS(0) UnS(0) GSx(1) = Liquid flow FS(1) UnS(1) GSx(2) = Flow temperature 7 Uns(2) GSx(3) = Inlet pressure FS(3)_UnS(3) ) 46GSx(4) = Valve pressure drop FS(4) UnS(4) GSx(5) = Molecular weight GSx(6) = Specific gravity at FTP GSx(7) = Viscosity at PTP FS(7) UnS(7) GSx(8) = Vapor pressure FS(8) UnS(8) GSx(9) = Compressibility factor FS(9) UnS(9) GSx(10) = Ratio of specific heats GSx(11) = Critical pressure FS(i1) Uns(11) GSx(12) = Critical temperature UnS(2) GSx(14) = FL Coefficient at % flow GSx(15) = Caloulated CV GSx(19) = Percent Flow GSx(26) = Liquid eritical pressure FS(26) Uns(26) GSx(27) = Acoustic efficiency GS0(13) = Gas property dba GS1(13) = Valve rated efficiency GS0(16) = Valve size FS(16) UnS(16) GS1(16) = Valve rated Cv GS2(16) = Valve rated Fd GSO(17) = Valve rated FL GSI(17) = Valve rated XT GS2(17) = Valve rated Ke GSO(18) = Inlet pipe size FS(17) UnS(18) GS1(18) = Outlet pipe size FS(17) UnS(18) Outlet pipe wall thickness, FS(18) UnS(18) Base temperature UnS21) GS0(22) = Base pressure FS(22) UnS(22) Barometric pressure FS(23) UnS(23) Normal dba Maximum liquid flow FS(1) UnS(1) SDG) = Maximum inlet pressure FS(3)_UnS(3) SD(4) = Maximum shut off differential pressure FS(4)__ UnS(4) Maximum temperature UnS(2) Maximum gas flow FS() UnS(0) Pressure drop sub program PDSS(1) = Inlet pipe length FS(25) Un8(25) PDSS(2) = Inlet pipe ID FS(18) UnS(18) PDSS(3) = Inlet pipe elevation FS(25) UnS(25) PDSS(4) = Outlet pipe length FS(25) UnS(25) PDSS(5) = Outlet pipe ID FS(18) UnS(18) PDSS(6) = Discharge pipe elevation FS(25) UnS(25) 47PDIS(1) = Inlet gate valves PDIS(2) = Inlet globe valves PDIS(3) = Inlet check valves PDIS(4) PDIS(5) PDIS(6) PDIS(7) = Inlet branch tees PDIS(8) ~ Outlet gate valves PDIS(9) = Outlet globe valves PDIS(10) = Outlet check valves PDIS(11) = Outlet 90Deg elbows PDIS(12) = Outlet 45Deg elbows PDIS(13) = Outlet thra tees PDIS(14) = Outlet branch tees PDCx(3) = Source pressure FSG) UnS@) PDCx(4)= Inlet equipment loss FS(4) UnS(4) PDCx(5) = Outlet equipment loss FS(4) UnS(4) PDCx(6) = Destination pressure FS@) Uns@) Miscellaneous Files CVWDAT.UNS ‘Sequential file. User unit data CVWDAT.STP Sequential file. Base conditions CVWSPEC.TXT. ‘Sequential file. Data sheet item selections HEADINGS.DAT ‘Sequential file. Printout titles CVSUMM.DAT Sequential file. Standard summary selections CVWCALC.DRV Sequential file. Default drives and paths CVWCALC.COL Sequential file. Color selections CONTROL VALVE Import Process Data Make a sequential file for cach calculation. Files to have a filename (Suggest the tag number) with no extension (ie TCV-100,). After INSTRUCALC reads the file it will rename the file to "FILENAME.OK". This will divide the files into two lists, those which have been processed and those which have not. To read a file. 1. Go to the required calculation and select the required units 2. Take the Import data menu option. 3. Find the required file. (Using standard Windows procedures) 484, Select the file and the data will be loaded. 5. Proceed with the calculation and save the data. (Now in the INSTRUCALC file) 6. The sequential file will be assigned the extension ".OK". and will disappear fiom the list, 7. Ia review is required, use the Windows file procedures for files with an extension ".OK” 8, Revised process data should be provided without extensions. The Instrument engineer will then have an instant review of work not yet performed. Data input Sequential File Requirements (In input order) Control Valve Gas Flow Variable name 1. Tag number (Seq file) 2. Fhuid name Service(4) 3. Maximum flow G(Case,0) 4. Percent of maximum flow G(Case,19) 5 Temperature G(Case,2) 6 Inlet pressure G(Case,3) 7 Barometric pressure G(0,23) 8 Pressure drop G(Case,4) 9 MW G(Case,5) 10 CpiCv G(Case,10) 11 Viscosity G(Case,7) 12 Density’ G(Case,9) 13 Critical pressure G(Case,11) 14 Critical temperature G(Case,12) 15 Inlet Pipe size G(0,18) 16 Outlet pipe size G(.18) 17 Outlet pipe wall G@,18) 18 Line number Service(2) 19 Service Service(1) 20 Valve failure position ARA(I8) Control Valve Liquid Flow Variable name 1 Tag number (Seq file) 2 Fluid name Service(3) 3 Maximum flow GCase,0) 4 Percent of max G(Case,19) 5 Temperature G(Case,2) 6 Inlet pressure G(Case,3) 7 Barometric pressure G(0,23) 498 Pressure drop G(Case,4) 9 SG@FIP G(Case,6) 10 Viscosity G(Case,7) 11 Vapor pressure G(Case,8) | 12 Critical pressure G(Case,11) 13 Outlet pipe size G18) 14 Outlet pipe wal G18) ' 15 Line number Service(2) i 16 Service Service(1) 17 Valve failure position ARA(IS) Control Valve Two Phase Flow —_Variable name i 1 Tag number {Seq file) 2 Gas name Service(4) i 3 Liguid name Service(3) 4 Gas flow G(Case, 0) i 5 % Flow G(Case, 19) 6 Temperature G(Case, 2) 7 Inlet pressure G(Case, 3) 8 Pressure drop G(Case, 4) 9 Gas MW G(Case, 5) 10 Gas Density G(Case, 9) 11 Gas Cp/Cv (Case, 10) ) 12 Gas critical pressure G(Case, 11) 13. Gas critical temperature G(Case, 12) i 14. Liquid flow G(Case, 1) i 15. Liquid specific gravity @ FTP G(Case, 6) 16 Liquid viscosity G(Case, 7) 17 Liquid vapor pressure GCase, 8) ' 18 Liquid critical pressure G(Case, 26) 19 Barometric pressure GEO, 23) 20 Inlet pipe size GQ, 18) | 21 Outlet pipe size Gq, 18) 22 Outlet pipe wall GQ, 18) | 23. Line number Service(2) 24 Service Service(1) 25. Valve fail position ARA(I8) CONTROL VALVE Pressure Drop Calculation ‘This program uses the units selected in the control valve calculation program. To access choose Options in the Control Valve Input sereen then select Cale system pressure drop. ;CONTROL VALVE Pressure Drop Calculation 176 Pipe LD. |) an) [11-990 fe nd 1O Cast ron /O Galy iron IO Aaphalted © Concrete wood | sek yalo0 ed EIS dea oi Ti tee [Blanch tee) 8 i 1 ‘This program uses the units selected in the control valve calculation program. To access choose Options in the Control Valve Input screen then select Cale system. pressure drop. Calculation options Select the Pipe Material. Options are: Steel, Tubing, Cast iron, Galv iron, Asphalied, Concrete, Wood Select the Pipe Condition. Options are: New, Good, Old Input Data (Variable data) The enabled input boxes define the data required for the calculation. stEnter the piping configuration and the pipe lengths, pipe sizes and elevation change. Enter the process data not passed down from the valve calculation. “The pipe sizes are available in a program look-up table. To find the size, select the Pipe ID button (or Wall) to display the pipe size sereen, enter the nominal size of the pipe and select the search button, The available wall thickness and the corresponding inside diameters for the nominal size are displayed. Select the required size and the data will be downloaded to the calculation. Metric dimensions are in millimeters and nominal sizes are based on 25 mm per nominal inch. If units other than inches or millimeters are used, the data transferred. back to the calculation will be converted to the calculation units. Calculate Click the Caleulate (Case) button. ‘The program will validate the input data, Calculate the output data Display the results, Analyzing and editing Data Minimum pressure drop A control valve needs a minimum pressure drop actoss the valve in order to control. ‘The amount is a complex problem, there are several guidelines: The greatest of, 15 psi or, 33% of the dynamic loss in a pumped circuit, The greatest of, 50% of the dynamic loss or, 10% of the destination pressure where the source pressure is static. ‘The greatest of 10% of the absolute pressure, or 5 psi for control of steam supply. “Tho greatest of 5% of the suction absolute system pressure, or 50% of the dynamic losses for control of a centrifugal compressor. ‘The valve characteristic This is another complex problem One set of guidelines are: If the difference between the maximum and minimum pressure 20 ElemMatlNom As Integer 2 bytes.Element material number PipeMatINum As Integer 2 bytes. Pipe material FloBasis As String * 3 3 bytes." Mas” denotes a mass calculation, "Vol" a volume Vent As String *3 3 bytes. "Yes" or "No" for drainhole FS(1 To 15) As Single 60 bytes.Units conversion factor GS(I To 20) As Single __80 bytes.(1-15)Cale Input data, 16) beta, (17)EdgeRad_(13)Norm flow, (19)VentSize UnS(I To 15) As String * 8 120 bytes.Unit Name Data sheet info SéS(1T07) AsSingle 28 bytes. ‘AraS(1 To 16) As String * 25400 bytes Data sheet array selections ‘Txtl(1 To 3) As String * 25 75 bytes.Data sheet service,line num, fluid Txt2(1 To 3) As String * 60 180 bytes.Data sheet notes TXT3(1 To 7) As String * 10 70 bytes.Data sheet num,spec,rev,date,req,by,appr End Type Record len=1025 Common data all Elements ElemMatlNom and PipeMatINum If material number = 1 Then Material = "301 stainless steel" If material number = 2 Then Material = "304 stainless steel" If material number = 3 Then Material ~ "310 stainless steel" If material number = 4 Then Material ~ "316 stainless steel" If material number = 5 ‘Then Material = "330 stainless steel” I material number = 6 Then Material = "347 stainless steel" If material number = 7 Then Material = "Aluminum bronze" If material number = 8 Then Material = "Beryllium copper" If material number ~ 9 Then Material = "Carbon stee!" Af material number = 10 Then Material = "Copper" If material number = 11 Then Material = "Cupronickel” ‘If material number = 12 ‘Then Material = "Hastelloy B" 88Wa WSs = Sap Falter 3, Caloulate Beta Ratio By =0.6991Y,8,°°" 4, Caleulate orifice bore d=B,.D For complete details of all formula and techniques refer to the [SO 167 and The Flow ‘Measurement Engineering Handbook By R.W.Niller. These describe the development of the formulas, the application limitations and installation requirements for predictable results as well as a large amount of other valuable information, Nomenclature Wa Flowrate upper range variable Join Wa Flowrate normal flow ton Hu pifferential upper range variable inches of water Hu pitferentiel normal inches of water Sw ovifice sizing factor dimensionless D Pipe inside diameter at flowing temperature inches d Orifice inside diameter inches Yo Density at flow conditions tits Hep Absolute Viscosity centipoise Ro Reynolds Number dimensionless Bo Beta Ratio dimensionless C _oniice discharge coeticent dimensiontess Cw orice discharge cootticient for infinite Reynolds Number dimensionless YY Gas expansion factor dimensionless P. Upstream pressure psia k Ratio of specific heats dimensionless Fx Thermal expansion factor dimensionless Peome Downstream pressure for sonic velocity psia 871S Flow Element Calculation Routines Routines aro similar all devices except that the discharge coefficient formulas vary. ‘The gas restriction orifice is checked for critical flow, see RO Sonic Gas Routine. Set initial values. C=0.6:Y=1 1. Calculate the Normal Differential Range 2 W, Hy=Hy (wi hy We 2. Calculate the SM Factor a 358,9628.D?F,./7,.Hy 3. Calculate Reynolds Number 6.31533. Wy R, = SSS Da, 4, Calculate the beta ratio peliteas) §. Calculate the discharge coefficient at infinite Reynolds Number “Typical for comer taps Cyye = 0.5959 + 0.312183" - 0.18488, 6. Caloulate the true discharge coefficient Where typically b= and n = 0.78 for comer taps 7. If the fluid is gas then calculate the expansion factor i “ Hy ¥=1-(0.41+0. 250) st} 8. Repeat from step 4 until the value of the beta ratio changes less than 0.000001 9. Caloulate orifice bore d=o.D R. 0. Sonic Gas Routine 4. Cheek for sonic velocity 2 Peoue = P}| == conte lal 2. If the discharge pressure is more than - Prone then use pipe tap calculation Else 86Procedure for a new Summary Select Options Clear checks Clears all checks on the form Clear Other Data Clears all other data on the form Make new field selections Each field has four boxes- ‘A check box to select the field A box to specify the field width Abox to enter data to compare ‘A box to specify the compare method (Double click for data) Select data relationship ‘And or or Click Print to print using Windows Print Manager File Options Save print options Saves a standard printout Go to Program Menu Form Returns to program menu for further work on this module Exit Retums to the Windows Program Manager Procedure for a standard printout Select Options Recall saved options Print Procedure to print all fields Select Options Check all Print Other Options Select font ‘Windows font selection procedure Select Printer Windows Print manager 853 Then Material = "Hastelloy C” If material number = 14 Then Material = "Haynes Stellite 25" If material number = 15 Then Material = "Inconel X" If material number = 16 Then Materiz "K - Monel" If material number = 17 Then Material = "Nickel" If material number ~ 18 Then Material = "Pyrex glass" If material number = 19 Then Material ~ "Tantalum" If material number = 20 Then Material = "Titanium" FloBasis "Mas" denotes a mass calculation, "Vol" a volume Vent "Yes" or "No" for drainhole Liquid calculations 1fProgNum = I Then Program = "Concentric Orifice Plate - FlangeTaps - 180 - Liquid” If ProgNum = 2 Then Program = "Concentric Orifice Plate - D and D/2 taps - ISO - Liquid” If ProgNum = 3 Then Program = "Concentric Orifice Plate - Comer taps - ISO - Liguid" If ProgNum ‘Then Program = "Concentric Orifice Plate - Pipe taps - ISO - Liquid" If ProgNum = 5 Then Program = "Eecentric Orifice Plate - Flange side taps - ISO - Liquid” If ProgNum ~ 6 Then Program = "Segmental Orifice Plate - Flange taps - ISO - Liquid” If ProgNum ~ 7 Then Program = "Quadrant Edge Orifice Plate - Comer taps - ISO - Liquid” If ProgNum = 8 Then Program = "Conic Orifice Plate - Comer taps - ISO - Liquid” If ProgNum = 9 Then Program = "Venturi-Machined Inlet - ISO - Liquid” If ProgNum = 10 Then Program = "Venturi-Cast Inlet - ISO - Liquid’ If ProgNum = 11 Then Program = "Venturi-Welded Inlet - ISO - Liquid” If ProgNum = 12 Then Program = "Universal Venturi - ISO - Liquid" If ProgNum = 13 Then Program = "Lo-Loss tube - ISO - Lignid” If ProgNum = 14 Then Program = "Flow nozzie-ASME long radius - ISO - Liquid" If ProgNum = 15 Then Program = "Flow nozzle-ISA - ISO - Liquid" If ProgNum = 16 Then Program = "Flow nozzle-Venturi - ISO - Liquid" All liquid flow elements GS(1) = Maximum flow FS(1) UnSq) GS(2) = Flow temperature UnS(2) GS(3) = Inlet pressure FS(3) UnS(3) GS(4) = Differential range FS() Uns(4) GS(5) = Specitic gravity at flow conditions GS(6) = Specific gravity at standard conditions GS(7) = Viscosity FS(7) UnS(7) GS(8) = Pipe inside diameter FS(8) UnS(8) 89Orifice size FS(12) UnS(12) Normal flow FS(1) UnS(1) Drain hole size FS(12) UnS(12) SDS(1) = Normal flow differential FS(4) UnS(4) SDS(3) = Plate thickness FS(12) UnS(12) SDS(4) = Beta ratio SDS(5) = Chart multiplier If ProgNum = 17 Then Program Liquid” Liquid RO data GS(1) = Maximum flow FS(1) UnS(1) GS(2) = Flow temperature UnSQ) GS(3) = Inlet pressure FS@) UnSG) GS(5) = Specific gravity at flow conditions GS(6) = Specific gravity at standard conditions GS(7) = Viscosity FS(7) UnS(7) GS(8) = Pipe inside diameter FS(8)_ UnS(8) Vapor pressure FS(10) UnS(10) Orifice size FS(12) UnS(12) (16) = Discharge pressure FS) UnS@) GS(19) = Drain hole FS(12) UnS(12) SDS(3) = Plate thickness FS(12) UnS(12) SDS(4) = Beta ratio Gas calculations "Concentric Restriction Orifice Plate - If ProgNum = 21 Then Program = "Concentric Orifice Plate - FlangeTaps - ISO - Gas" If ProgNum ~ 22 Then Program = "Concentric Orifice Plate - D and D/2 taps - ISO - Gas" If ProgNum = 23 Then Program = "Concentric Orifice Plate - Comer taps - ISO - Gas" If ProgNum = 24 Then Program = "Concentric Orifice Plate - Pipe taps - ISO - Gas" If ProgNum = 25 Then Program = "Eccentric Orifice Plate - Flange side taps - ISO - Gas" If ProgNum = 26 Then Program = "Segmental Orifice Plate - Flange taps - ISO - Gas" If ProgNum = 27 Thea Program = "Quadrant Edge Orifice Plate - Corner taps - ISO - Gas" IfProgNum = 28 Thea Program = "Conic Orifice Plate - Comer taps - ISO - Gas" If ProgNum = 29 Then Program = "Venturi-Machined Inlet - ISO - Gas" If ProgNum = 30 Then Program = "Venturi-Cast Inlet - ISO - Gas" If ProgNum = 31 Then Program = "Ventuti-Welded Inlet - ISO - Gas" If ProgNum = 32 Then Program = "Universal Venturi - ISO - Gas" 903 Then Program ="Lo-Loss tube - ISO - Gas" If ProgNum If ProgNum = 34 Then Program If ProgNum = 35 Then Program = "Flow nozzle-ISA - ISO - Gas" If ProgNum = 36 Then Program Flow nozzlc-ASME long radius - ISO - Gas" "Blow nozzle-Venturi - ISO - Gas" All gas flow elements GS(1) = Maximum flow FS(1) UnS(1) GS(2) = Flow temperature UnSQ) GS(3) = Inlet pressure PS@) Uns@) GS(4) = Differential range FS(4) UnS(4) GS(5) = Molecular weight GS(6) = Ratio of specific heats GS(7) = Viscosity FS(7) UnS(7) GS(8) = Pipe inside diameter FS(8) UnS(8) GS(9) = Compressibility factor FS(9) UnS@) GS(10) = Critical pressure FS(10) UnS(10) GS(11) = Critical temperature UnS(11) GS(12) = Orifice size FS(12) UnS(12) GS(13) = Base pressure FS(13) UnS(i3) ase temperature unS(14) arometric pressure ¥FS(15) UnS(15) juadrant edge radius or Segment diameter FS(12) jormal flow FS(1) UnS(1) Drain hole size FS(12) UnS(12) formal flow differential FS(4) UnS(4) ate thickness FS(12) UnS(12) SDS(4) = Beta ratio SDS(5) = Chart multiplier UnS(12) If ProgNum = 37 Then Program a Gas RO data GS(1) = Maximum flow FS(1) UnS(1) GS(2) = Flow temperature UnS(2) GS(3) = Inlet pressure FS(3) UnS@) GS(5) = Molecular weight GS(6) = Ratio of specific heats GS(7) = Viscosity FS(7) UnS(7) GS(8) = Pipe inside diameter FS(8) UnS(8) GS(®) = Compressibility factor FS(9) Uns(®) GS(10) = Critical pressure PS(10) Uns(10) GS(T vritical temperature ‘UnS(11) GS(12) = Orifice size FS(12) Uns(12) 91 "Concentric Restriction Orifice Plate -GS(13) = Base pressure FS(13) UnS(13) GS(14) = Base temperature UnS(14) GS(15) = Barometric pressure #S(14) UnS(i4) GS(16) = Discharge pressure FSG) Uns() GS(19) = Drain hole size FS(12) Uns(12) SDS@) = Plate thickness FS(12) Uns(12) SDS(4) = Beta ratio Miscellaneous Files ISODAT.UNS ‘Sequential file. User unit data ISODAT.STP Sequential file. Base conditions ISOSPEC.TXT. Sequential file. Data sheet item selections HEADINGS.DAT Sequential file. Printout titles ISOSUM.DAT Sequential file. Standard summary selections ISOCALC.DRV Sequential file. Default drives and paths ISOCALC.COL —_ Sequential file. Color selections ISO Import Process Data ‘To Import process data into a calculation: Make a sequential file for each calculation. Files to have a filename(Suggest the tag number) with no extension (i.e, FE-100). After INSTRUCALC reads the file it will rename the file to "FILENAME.OK". This will divide the files into two lists, those which have been processed and those which have not To read a file: 1, Go to the required calculation and select the required units. 2. Take the Import data menu option. 3. Find the required file, (Using standard Windows procedures) 4. Select the file and the data will be loaded. 5. Proceed with the calculation and save the data. (Now in the INSTRUCALC file) 6. The sequential file will be assigned the extension ".OK". and will disappear from the lis. 7. Ifa review is required, use the Windows file procedures for files with an extension "OK" 8, Revised process data should be provided without extensions, The Instrument engineer will then have an instant review of work not yet performed. 2Data input sequential file requirements: (in input order) Gas Flow elements Variable name 1 Tag number (Seq file) 2 Fluid name Tatl(3) 3° Maximum flow Gay 4 Nomnal flow Gis) 5 Temperature Ge) 6 Inlet pressure G@) 7 Barometric pressure G15) Differential range Ge) 9 MW Ge) 10 Cpicv G6) 11 Viscosity at) 12. Pipe size Ge) 13. Density Ge) 14. Critical pressure Gly 15 Critical temperature G(11) 16 Line number Txtl@) 17 Service Taxtl(1) Liquid flow elements 1 Tag number {Seq file) 2. Fluid name Txtl@) 3 Maximum flow ca 4 Normal flow G8) 5. Temperature Ge) 6 Inlet pressure 6G) 7 Barometric pressure G(15) 8. Differential range Ge) 9 SG@FIP G(s) 10 SG@ Base G6) 11 Viscosity G7) 12 Pipe size Ge) 13 Line number Txtl(2) 14 Service Tatl(1) 93 Gas restriction orifice ‘Tag number Seq file) Fluid name Txtl@) ‘Normal flow GQ) ‘Temperature GQ) Inlet pressure GG) Barometric pressure G(1S Discharge pressure G(4) Mw a) Cpicy G6) Viscosity GC) Pipe size G(s) Density Ge) Critical pressure G10) Critical temperature G(11) Line number ‘TxtT1(2) Service ‘Txti() Liquid restriction orifice Tag number (Seq file) Fluid name Txtl@) Normal flow ca Temperature Ge) Inlet pressure GG) Discharge pressure G(4) Barometric pressure G(15) Vapor pressure G(10) SG @ FIP GO) SG @ base Ge) Viscosity a) Pipe size GB) Line number Txtl(2) Service Txtl(1)ISO Pipe Inside Diameter ‘The orifice pipe run is the straight sections of pipe, upstream and downstream of the otifice plate, as specified in ISO 5167 and AGA3 and ANSI 2530. The ISO pipe inside diameter is the average of 12 measurements of the upstream section of the meter measured at a room temperature. Initially, in most cases, the orifice pipe run is not available and the standard size is used. This is available in a program look-up table. To find the size, select the meter nun size button to display the pipe size screen, enter the nominal size of the pipe and select the search button. The available wall thickness and the corresponding inside diameters for the nominal size are displayed. Select the required size and it will be transferred to the calculation. When the meter tube becomes available, measure the inside diameter and back calculate either the amended flow rate or differential pressure, Metric dimensions are in millimeters and nominal sizes are based on 25 mm per nominal inch. If Units other than inches or millimeters are used, the data transferred back to the calculation will be converted to the calculation units.Chapter 3 RELIEF VALVES Relief Valve Programs Liquid Relief - Known Flow Gas Relief - Known Flow Steam Relief - Known Flow Heat Exchanger - Entrapped Liquid Heat Exchanger - Tube Failure Pipeline - Enirapped Liquid Fire Size - Liquid Vaporization Fire Size - Gas ExpansionRELIEF VALVES Program Overview Most instrument engineers do not consider pressure relief valves as instruments. ISA publishes a specification sheet for them, yet very rarely does ISA mention them again, Engineering contractors generally delegate them to their Instrument Department, yet operating companies rarely do. ‘They are vital to the safe operation of the plant, and the person responsible for them must be familiar with API 520 parts 1 and 2, NFPA #30, the ASME pressure vessel code and any other authoritative body. Every ASME coded vessel must be protected with an ASME certified relief valve. The manufacturers are a valuable source of information for much of the sizing data. To size a relief valve, plant operations must be thoroughly understood, an analysis of all possible contingencies must be made and the worst case selected (typical cases are shown in Table 4-1), It is not normal to consider double contingencies such as an external fire and, at the same time, an operations error, unless there is a real possibility of it happening. Good engineering judgment is called for. The valves are inexpensive insurance for the plant, and the underinsurance can be an unmitigated disaster. ASME and other governing authorities require pressure relief valves to be installed on all equipment that ean be blocked in, and are rated at 15 psig ot more, although it is permissible to have a block valve car sealed open. Rupture discs are sometimes installed under a relief valve where bubble-tight shutoff is required or where corrosive or dirty service conditions exist. In such cases a pressure gauge should be installed between the two so that rupture disc failures can be detected. The relief valve capacity must be decreased by 25% of the rated capacity if used with a rupture disc, unless the capacity of the combination has been established in aceordance with the appropriate paragraphs of UG-132 of ASME Code Section 8. Dual valves, with a special three-way valve that ensures full relief area is always available, can be installed where servicing may be required between unit shutdowns. When sizing pressure relief valves, remember that they are basically differential pressure devices. They open when the inlet pressure minus the back pressure equals the set pressure. Most valves relieve into a relief header which is tied into the flare, Tf the relief header already has some valves discharging into it, a higher backpressure will be exerted on those valves not yet open, and a higher inlet pressure will be required to open them. The installation of the valve can significantly affect its performance and selection. If) the inlet piping has too much friction pressure loss, the valve will open at its correct set pressure but may start to close as the pressure drops, only to open again as the pressure builds up again, ‘The inlet piping pressure loss duc to friction should not cexeced 3% of the set pressure, based on the valve capacity flow, not the flow used in the sizing calculation. 96Since most valves are set at the maximum allowable working pressure of the vessel, and since the ASME codes allow the pressure to exceed this by 10% (or up to 21% for external fire sizing), any downstream piping should be sized to limit the built up backpressure to 10% of the lowest set point if standard valves are to be used. ‘There are essentially three types of valves - standard valves, bellows valves and pilot operated valves (some typical valves are shown on the next page). The bellows valve has a bellows installed over the seat mechanism to keep the backpressure at atmospheric pressure. ‘The pilot operated valve operates with more precision and flexibility than the others. Standard valves are usually selected for cases where the backpressure is likely to be nearly constant. (This is not necessarily atmospheric pressure.) The spring is adjusted to give the desired opening pressure. A variable backpressure of 10% of set pressure is usually allowed, for a valve is usually sized on the basis of critical flow. ‘Therefore, a 10% overpressure would only delay the valve opening; it would not affect flowrate or accumulation (accumulation being defined as the allowable increase in pressure during discharge through the relief valve). Where backpressure variations exceed 10% of the set pressure, a pilot operated or balanced bellows valve is normally chosen, The bellows must be vented to the atmosphere. These valves inherently require more maintenance than standard valves. Failure of the bellows by corrosion, rupture, or plugging of the vent converts them to standard valves. The bellows valves have backpressure and size limitations and, ‘where the backpressure is sufficiently high to prevent sonic velocity through the valve, they usually have a smaller capacity than the standard valve. ‘The set pressure is the pressure at which a liquid valve starts to lift and a gas or vapor valve pops open. Maximum flow is achieved at a slightly higher pressure called accumulation. ASME has very definite limits as to the accumulation rise if the set pressure is also the maximum allowable working pressure. Accumulation is defined as: (set pressure psig x over pressure factor + 14.7) psia. ‘The backpressure required for the calculation is the total backpressure. This is the sum of the superimposed backpressure and the built up backpressure. The superimposed backpressure is the pressure imposed on the valve before it opens. Tt affects the set pressure of the valve, The built up backpressure is the increase in the outlet pressure caused by the friction loss in the discharge piping during relief flow through the valve. This will not affect the set pressure, For liquids, the total backpressure will always affect the capacity of the valve, for gases it will not affect the capacity unless the backpressure increases to the point where sonic flow no longer exists through the valve. Sonic velocity occurs when the pressure drop across the valve is approximately 50% of the absolute inlet pressure. Because of the ASME. limitation of 10% most valves will have sonic velocity through them. The API RP-520 formula include a method of predicting subsonic flow and compensating for it. ‘The program always checks for this and makes an allowance for backpressure when it is necessary. ‘The backpressures are largely determined by the discharge piping. The ASME suggested maximum piping pressure loss for a standard valve is 10%, a bellows 30% and a pilot operated valve, 50% of the set pressure. The ASME inlet piping pressure Joss must not exceed 3%: It is suggested that after a calculation is made and the ‘maximum flow capacity and size is known that the line pressure loss program in chapter five is run to determine the minimum pipe sizes and the maximum equivalent line lengths for the inlet and outlet sizes. Sonic velocity should be avoided in the lines. Use this data to design the piping. You may be surprised to find that even with close coupled valves that a larger line is sometimes required in order to stay below the 3% figure. Accuracy of the Calculations ‘The formulas used have been accepted over the years. The ASME gas formulas apply only to pressures exceeding ISpsig, All formulas are empirical by nature and generally adequate over the range of normal circumstances, the challenge is to recognize what are not normal circumstances. ‘The fire sizing calculations have options to use either the API 520 or NFPA #30 method to determine relieving flowrate, The program places limits on the input data to reject obvious errors, such as, negative flowrates. Relief valve sizing, particularly fire sizing, is not an exact science, the user is wise to be cautious and conservative. It is entirely possible to enter impossible data and still get an answer. The programs are an aid to engineering not a replacement of. The principles of GIGO apply. The results should be interpreted by a competent person, Most of these data are based on ASME Section 8: Pressure Vessel Code, ASME Section 1, Power Boiler Code, API RP520, The Recommended Practice for the Design and Installation of Pressure Relieving Systems in Refineries, API 2000, Venting Atmospheric and Low Pressure Storage Tanks and The National Fire Protection Agency #30. It is recommended that copies be obtained for reference purposes, Rither the ASME or the API 520 formula can be selected for liquid sizing. It should be noted that for ASME coded vessels built after 1985, the ASME formula applies. Be careful to specify the ASME cettified liquid trim valves for these. Program Options Standard or balanced bellows Rupture disk allowance Selecting orifice designationASME or API liquid calculations (New ASME approved vessels require the ASME formula, vessels designed prior to the adoption of the ASME formula may still use the API formula) Calculate the inlet and outlet pipe losses ASME limits the inlet losses to 3% and the outlet losses to 10% Sizing Considerations Relief valve sizing, particularly fire sizing is not an exact science. There are many contingencies, such as loss of coolant, loss of power, blockage of lines, equipment failure, operator error. The one requiring the largest valve is the one required. It is not normal to consider double contingencies unless there is a real possibility of it happening. Good conservative engineering judgment is called for. The vaives are inexpensive insurance for the safety of the plant. Under insurance can be an unmitigated disaster. ASME and other governing bodies require relief valves to be installed on all pressure equipment that is rated at 15 psig or more and can be blocked in by valves ‘which are not car sealed open. Rupture disks are sometimes installed under a valve where bubbletight shutoff is required or where corrosive or dirty service conditions exist. In such cases a pressure gage should be installed between the two so that rupture disk failures can be detected. The relief valve capacity must be reduced to 90% of its capacity if used with a rupture disk, unless the capacity of both have been established in accordance with the appropriate paragraphs of UG-132 of ASME Code Section 8 Dual valves, with a special three way valve which ensures full relief area is always available, can be installed where servicing is required without a plant shutdown, ‘The set pressure is the pressure at which a liquid valve starts to lift and a gas or vapor valve pops open. Maximum flow is achieved at a slightly higher pressure called accumulation, If the set pressure is also the maximum allowable working pressuré of the vessel (which it normally is) then ASME allows Section | fired pressure vessel Accumulation = Set pressure + 3% + 14.7 psig, Section 8 unfired pressure vessel Accumulation = Set pressure + 10% + 14.7 psig Section 8 pressure vessel fire sizing Accumulation ~ Set pressure + 21%.+ 14.7 psig ‘The back pressure required in the calculations is the total back pressure. This is the sum of the superimposed back pressure plus the buil-up back pressure. The superimposed back pressure is the pressure imposed on the valve before it opens. It affects the set pressure. The built-up back pressure is the increase in pressure caused by the friction loss in the discharge piping during relief flow through the valve. This 99does not affect the set pressure of the valve. For liquids, the total back pressure will always affects the capacity of the valve. For gases it will not affect the capacity unless the back pressure rises to the point where sonic flow no longer exists though the valve. Sonic flow occurs when the pressure drop is approximately 50% of the absolute inlet pressure. Since the ASME limitation is 10% then sonic flow will always exist ‘Types of Valves There arc two types of common valves Standard valves Bellows valves ‘The bellows valve has a bellows installed over the seat assembly to keep the back pressure on the valve at atmospheric. Valve Application If back pressure is relatively constant (not necessarily atmospheric) a standard valve is normally used. The spring is adjusted for the back pressure. If the valves discharge {nto a coramon header and have different set-pressures, then standard valves may not ‘be suitable for the low set pressure valves because the 10% back pressure of the high set pressure valves will exceed the 10% of the low pressure valve. If the pressure rise is less than 30% of a valve set pressure then a bellows valve may be the option. If it is less than 50% then a pilot valve is an option. RELIEF VALVE Program Features Perform sizing calculations Calculate either ASME single, ASME multi, or API method Calculate fire sizes and vessel wetted areas Calculate liquid thermal expansion sizes Calculate inlet and outlet pipe losses Supply fluid properties at flow conditions Supply steam data Supply pipe sizes Use English or SI engineering units in any mixture Use mass or volume flow units Import process data Print a calculation sheet using the Windows Print Manager 100Save the data Prepare instrument data sheets WYSIWYG style Initially general-sheets for bid purposes Supply database of standard specification items After vendor selection, revise for pertnanent records Print a data sheet using the Windows Print Manager Save the data Print a summary of saved records Print all records Print selected record: Print only records having required characteristics 101‘This is a program for calculating the size of relief valves for: Liquid Relief Known Flow Gas Relief Known Flow Steam Relief Known Flow Heat Exchanger _Entrapped Liquid Heat Exchanger Tube Failure Pipeline Entrapped Liguid Fire Size Liquid Vaporization Fire Size Gas Expansion | @ 1 Liquid relief - Known flow © Heat exchanger - Tube failure [© 2Gacreliot - Known flow © 5 Pipetine - Entrapped liquid a The programs are based on the ASMI C Options ar Provided to calculate according to NFPA N30 or APL ‘The Liquid Relief - Known flow calculation has options to use the API or the ASME formula. ‘The Gas Relief - Known flow calculation uses the ASME formula. It has options for section 1, section 8 or the fire code. The reaction force and the noise level are calculated. ‘The Steam Relief - Known flow calculation is an ASME calculation, it also has options for Section 1, section 8 and the fire code and calculates the reaction force and noise level ‘The Heat Exchanger - Entrapped liquid calculation is for a blocked in liquid filled exchanger which has the heat tured on, It calculates the flow caused by the liquid expansion and is either an ASME or API calculation. 102‘The Heat Exchanger - Tube failure calculation is for tube rupture where the tube pressure is 50% greater than the shell pressure. It assumes no vaporization of the shell side product. It is either an ASME or API calculetion. ‘The Pipeline - Entrapped liquid calculation is for liquid expansion in long, blocked ‘in, pipelines on a hot day. It usually only takes a very small relief valve to avoid blowing the gaskets. The calculation can be either ASME or API. The Fire size - Liquid vaporization is the most complex calculation. It gathers the flame wetted area of up to 15 liquid containing vessels. ‘The heat input is calculated cither by The API 520 or the National Fire Protection Association NFPA #30, method and a relieving flow rate is determined. The ASME formula determines the valve size. The reaction force and relieving noise level are also calculated. ‘The Fire size - Gas expansion also gathers the flame wetted area, this time of up to 15 gas containing vessels. The required size is determined by the API 520 formula ‘The maximum flow is then back calculated from the valve size. The reaction force and relieving noise level are then calculated. RELIEF VALVE Program Menu Options New calculation Select the required calculation option and the fluid option, then select OK (or double-click if at least one of the options is already selected) File Default files Recalls file data using the files in the default drives and paths. Other files Recalls file data using the Windows file selection procedure. Data file maintenance Edit Tag Numbers Provides the facility to change the Tag Numbers on file Or delete records from fie. Sort data file Rearrange the Tag Numbers in ascending order. Delete the items marked if the edit was saved. Data files path Path for the default calculation data files User unit file path Path for the default engineering units file. Printout headings file path Path for the printout headings file. 103‘There are three paths, If Drive and Path different from the Default Path and Drive provided in the initial Set Up Procedure was used, the program will update them to the Drive and Path which was installed. They are saved in sequential file RVWCALC.DRV which resides with the programs. To check or change the paths, cither call up the Drive and Path for edit or use a text editor to or change the file contents, Convert V3 file stage 2 Instrucale version 3 file conversion to Windows format. Exit Exits from Instrucale to Windows Program Manager. Color Provides color options for Instrucale displays, using the Windows palette. Edit Tables (Version 5.1) InstruCalc uses Data Tables for Gas, Liquid, Pipe Size and Material properties, these contain data from which exact properties for the flow conditions are calculated. It also has tables for equipment data. These option provides an easy means of customizing them. Items can be added, inserted, deleted and changed. Each program can edit the tables used in the program. Take note that some, such as, the Gas, Liquid and Pipe Size are used by other programs and may include data required only by them. Editing is performed by either clicking the appropriate line in the Grid or entering the line number in Row to Edit and clicking Recall Row. Edit the data and Load Row to the Grid. When a box in the edit line is clicked, information on the data required is displayed above. Save Grid overwrites the old file. A backup file is recommended before you start, The file name is in the heading of the Edit Form and the files are in the program directory. ‘Note that data cannot be edited directly in the grid, Print Summary Goes to the print summary program. 104RELIEF VALVE Program Lead Sheet ‘The program will only stop at the Lead Sheet if it fails to find the default paths file. To continue, type in the paths and save the file, ‘The Data Files are specific to a project and an instrument type ‘The Units File may be common for all projects and specific for an instrument type ‘The Headings File may be specific for a project and common for all instruments Relief Valve Size - Liquid Calculation Known Flow | | | I ‘ASME mut JO APL | [[O Stondard]}O Bellows 4 7 No [0 Yes | The pipe loss option will determine the inlet and outlet losses as well as the total back pressure. The ASME valve discharge coefficient is 0.62, for API itis 0.64. They will allow a different value for tested and approved valves. This data is available in the relief valve manufacturers catalogs. The rupture disk derating factor is | for no rupture disk, the ASME derating factor is 0.9, they will allow the use of a different factor for tested and approved assemblies. This data will be in the ruptre disk manufacturers catalogs. 105For Bellows Valves, the back pressure characteristic varies between manufacturers, the program follows the curve in API 520. The manufacturers data should be used when available, Engineering Units ‘There are four standard unit sets and one user selected set available: ‘Mass Flow - English Units. Pounds per hour and degrees Fahrenheit ‘Volume Flow - English Units, _US gallons per minute and degrees Fahrenheit Mass Flow - SI Units. Kilograms per second and degrees Centigrade Volume Flow - SI Units. Litres per second and degrees Centigrade User Units. A set of units selected from the Liquid Flow Engineering Unit screen To make or change a User Unit set select the option Review units The Liquid Flow Engineering Unit screen will be displayed. It shows the available options and the current unit selection, Select the required units and save the User file Unit Selection A new calculation defaults to Mass English Units. ‘The Unit Selection can be made at any time. The input data will be converted to the new units, Ifa volumetric flow unit set is selected and the specific gravity is not available the flow is set to zero. Units for any individual input entry can be changed by selecting the Review Units option and choosing from the Liquid Flow Engineering Unit screen, Fluid Properties ‘The Fluid properties option is enabled when the pressure and temperature are entered. The properties required for a calculation are available for pure liquids and mixtures and are provided in the selected units. Caution should be used for mixtures of dissimilar fluids because the mixture law may not apply. For a pure liquid find the name and select (or double-click) the name, the fluid properties will be entered. For a mixture select the first component. In the component box, enter the percentage. Continue until the remaining percentage equals zero, then select 106xture calculate in the component box and the program will calculate and enter the r values, The fluid properties database is user updateable. Sizing Code In the Summer 1984 Addenda to the Pressure Vessel Code, ASME published a formula for liquid sizing, All vessels registered after 1984 must be sized with the ASME formula and use special liquid trim valves with capacity approved by ASME for liquid service and stamped accordingly. Vessels built before this may still use the API formula and the old valves. Valve Type If the relief is to discharge into a relief header and be subject to varying back pressure, a bellows valve may be required, otherwise select a standard valve. Rupture disk ‘A rupture disk is sometimes installed under the valve for bubble-tight or corrosive service, otherwise select No. Input Data “The enabled input boxes define the data required for the calculation. When selecting the options the standard factors are entered Overwrite the factors with the manufacturers, if desired. Calculate Click the Calculate button ‘The program will validate the input data It will select the valve area and valve orifice designation. Calculate the output data Display the results Editing Data ‘The output data should be examined for adequacy. Ifa differont valve area is required then overwrite the data Change data as required and recalculate, ‘When the selection is final then take the pipe losses option, The inlet losses should not exceed 3% and the discharge losses should be less than 10%. 107Filing and Moving On The options in the File menu are: Program menu - Clears the calculation and returns to the main menu. Prepare data sheet - Is enabled after a calculation is made, it displays the screen to prepare a data sheet form for the calculated item, ‘New record - Clears the screen for a new calculation, Save - Using the default path, it saves a new record if not previously saved or saves changes to an existing record Save New.--Using the default path, it saves an existing record as a new record (Used to duplicate similar items. i.e. Recall an existing record, Edit as required and Save New) Save As....- Uses the Windows file access s anywhere. Import data - sequential files. File default path - Changes the default paths for the calculation records ‘The default paths are: ‘The Data Files. (RVDDAT.TAG and RVDDAT.DAT). The User Unit Files. (RVDDAT.UNS) The Printout Headings File (HEADINGS.DAT) Print calculation - [s enabled after a calculation is made. It displays the screen to print a calculation. Exit - Leaves the program and returns to the Windows Program Manager stem. Saves to a file Select the units and read Input data supplied in 108Relief Valve Size - Heat Exchanger Entrapped Liquid Calculation rc oe Caleulated area ind |) Calculated flow brh Relic! presse psig Viscosity conection Valve capacity. tbyh Mox back pressure psig HE Valve-oniice designation ‘The program determines the relief valve size if the heat is turned on and the other side of the heat exchanger is blocked in, It is for liquid relief only. ‘The pipe loss option will determine the inlet and outlet losses as well as the total back pressure, The ASME valve discharge coefficient is 0.62, for API it is 0.64. They will allow a different value for tested and approved valves. This data is available in the relief valve manufacturers catalogs. ‘The rupture disk derating factor is 1 for no rupture disk, the ASME derating factor is 0.9, they will allow the use of a different factor for tested and approved assemblies. ‘This data will be in the rupture disk manufacturers catalogs. For Bellows Valves, the back pressure characteristic varies between ‘manufacturers, the program follows the curve in API 520. The manufacturers data should be used when available, 109Engineering Units ‘There are four standard unit sets and one user selected set available - Mass Flow - English Units. Pounds per hour and degrees Fahrenheit Volume Flow - English Units. US gallons per minute and degrees Fahrenheit ‘Mass Flow - SI Units. Kilograms per second and degrees Centigrade Volume Flow - SI Units. Litres pet second and degroes Centigrade L ‘User Units A sct of units selected from the Liquid } Flow Engineering Unit screen To make or change a User Unit set select the option Review units. ‘The Liquid Flow Engineering Unit screen will be displayed. It shows the available options and the current unit selection, Select the required units and save the User file, Unit Selection A new calculation defaults to Mass English Units. ‘The Unit Selection can be made at any time. ‘The input data will be converted to the ) new units, Ifa volumetric flow unit set is selected and the specific gravity is not available the flow is set to zero. Units for any individual input entry can be changed by the selecting the Review Units option and choosing from the Liquid Flow Engineering Unit screen. Fluid Properties ‘The Fluid properties option is enabled when the pressure and temperature arc entered. The properties required for a calculation are available for pure liquids and mixtures and are provided in the selected units. Caution should be used for mixtures of dissimilar fluids because the mixture law may not apply. For a pure liquid find the name and select (or double-click) the name, the fluid properties will be entered. For a mixture select the first component. In the component box, enter the percentage, Continue until the remaining percentage equals zero, then select calculate in the component box and the program will calculate and enter the mixture values. The fluid properties database is user updateable, 110Sizing Code In the Summer 1984 Addenda to the Pressure Vessel Code, ASME published a formula for liquid sizing, All vessels registered after 1984 must be sized with the (ASME formula and use special liquid trim valves with capacity approved by ASME for liquid service and stamped accordingly. Vessels built before this may still use the API formula and the old valves. Valve Type If the relief is to discharge into a relief header and be subject to varying back pressure a bellows valve may be required, otherwise select a standard valve. Rupture disk ‘A rupture disk is sometimes installed under the valve for bubble-tight or corrosive service, otherwise select No. Input Data The enabled input boxes define the data required for the calculation. “When selecting the options the standard factors are entered Overwtite the factors with the manufacturers if desired. Caleulate Click the Calculate button, The program will validate the input data. It will select the valve area and valve orifice designation. Calculate the output data Display the results Editing Data ‘The output data should be examined for adequacy. Ifa different valve area is required then overwrite the data Change data as required and recalculate. ‘When the selection is final then take the pipe losses option. The inlet losses should not exceed 3% and the discharge losses should be less than 10%. Filing and Moving On The options in the File menu ave: Program menu ~ Clears the calculation and returns to the main menu. utPrepare data sheet - Is enabled after a calculation is made, it displays } the screen to prepare a data sheet form for the calculated item. New record - Clears the screen for a new calculation Save - Using the default path, it saves a new record if not previously saved or saves changes to an existing record, i Save New.-.Using the default path, it saves an existing record as a new i record (Used to duplicate similar items. ie. Recall an existing recard. Edit as required and Save New) i Save As....- Uses the Windows file access system. Saves toa file anywhere. a Amport data - Select the units and read Input data supplied in sequential files. i File default path - Changes the default paths for the calculation records | ‘The default paths are The Data Files. (RVDDAT.TAG and 1 RVDDAT.DAT). ‘The User Unit Files. (RVDDAT.UNS) The Printout Headings File (HEADINGS.DAT) Print calculation - Is enabled after a calculation is made. It displays the screen to print a calculation. Exit - Leaves the program and returns to the Windows Program Manager )4 12Relief Valve Size - Pipeline Entrapped Liquid Calculation Calculated area Caloulated flow tb/h Reet srereure pin Viscosity eoroction Valve capacity yh] Maxbock pressure psig Valve oilice designation FO Standard {© No =| ‘The program determines the relief valve size if the heat is tumed on and the other side of the heat exchanger is blocked in. It is for liquid relief only. ‘The pipe loss option will determine the inlet and outlet losses as well as the total back pressure. ‘The ASME valve discharge coefficient is 0.62, for API it is 0.64. They will allow a different value for tested and approved valves. This data is available in the relief valve manufacturers catalogs. ‘The rupture disk derating factor is | for mo rupture disk, the ASME derating factor is 0.9, they will allow the use of « different factor for tested and approved assemblies. ‘This data will be in the rupture disk manufacturers catalogs. For Bellows Valves, the back pressure characteristics varies between manufacturers, the program follows the curve in AP] 520 the manufacturers data should be used when available. 3Engineering Units ‘There are four standard unit sets and one user selected set available: ‘Mass Flow - English Units. Pounds per hour and degrees Fahrenheit Volume Flow - English Units. US gallons per minute and degrees, Fahrenheit Mass Flow - SI Units. Kilograms per second and degrees Centigrade Volume Flow - SI Units. Litres per second and degrees Centigrade User Units. A set of tinits selected from the Liquid Flow Engineering Unit screen ‘To make or change a User Unit set select the option Review units. ‘The Liquid Flow Engineering Unit screen will be displayed. It shows the available options and the current unit selection. Select the required units and save the ‘User file. Unit Selection Anew calculation defaults to Mass English units. ‘The Unit Selection can be made at any time. The input data will be converted to the now units. Ifa volumetric flow unit set is selected and the specific gravity is not available the flow is set to zero. Units for any individual input entry can be changed by the selecting the Review Units option and choosing from the Liquid Flow Engineering Unit screen. Fluid Properties ‘The Fluid properties option is enabled when the pressure and temperature are entered, The properties required for a calculation are available for pure liquids and mixtures and are provided in the selected units. Caution should be used for mixtures of dissimilar fluids because the mixture law may not apply. Fora pure liquid find the name and select (or double-click) the name, the fluid properties will be entered. For a mixture select the first component. In the component box, eater the percentage, Continue until the remaining percentage equals zero, then select calculate in the component box and the program will calculate and enter the mixture values. The fluid properties database is user updateable. 14Sizing Code In the Summer 1984 Addenda to the Pressure Vessel Code, ASME published a formula for liquid sizing, All vessels registered after 1984 must be sized with the ASME formula and use special liquid trim valves with capacity approved by ASME for liquid service and stamped accordingly. Vessels built before this may still use the API formula and the old valves. Valve Type If the relief is to discharge into a relief header and be subject to varying back pressure a bellows valve may be required, otherwise select a standard valve. Rupture disk A rupture disk is sometimes installed under the valve for bubble-tight or corrosive service, otherwise select No. Input Data The enabled input boxes define the data required for the calculation. When selecting the options the standard factors are entered Overwrite the factors with the manufacturers if desired. Caleulate Click the Calculate button. ‘The program will validate the input data. It will select the valve area and valve orifice designation. Calculate the output data Display the results Editing Data The output data should be examined for adequacy. Ifa different valve area is required then overwrite the data. Change data as requited and recalculate. ‘When the selection is final then take the pipe losses option

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