NELPROF 6.0 USERS GUIDE Java Version 1.

Published by METSO P.O.Box 310 FIN-00811 HELSINKI Finland Editor: Ismo Niemel Esa Lumme Petri Kanerva Vesa Lempinen Jari Kirmanen Jussi Koukkuluoma Copyright 2010 by Metso and the authors. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any form or by any means electronic, mechanical, photocopying, recording or otherwise, without the prior permission of the publisher. While this information is presented in good faith and believed to be accurate, Metso does not guarantee satisfactory results from reliance upon such information. Nothing contained herein is to be construed as a warranty or guarantee, express or implied, regarding the performance, merchantability, fitness or any other matter with respect to the products, nor as a recommendation to use any product or process in conflict with any patent. Metso reserves the right, without notice, to alter or improve the designs or specifications of the products and methods described herein. Produced and printed in Finland by Metso Helsinki 2010

Contents
Contents...........................................................................................................................1 1 NELPROF 6.0 USERS GUIDE..................................................................................1 2 Introduction to Nelprof Control and On-off calculation..............................................2 3 The Project Tree...........................................................................................................4 4 Control valve sizing and analysis.................................................................................4 5 On-off valve sizing and analysis................................................................................15 6 User settings...............................................................................................................18 7 User preferences.........................................................................................................19 8 File Functions.............................................................................................................19 9 Mass Operations.........................................................................................................19 10 SIL calculation tool..................................................................................................21 11 Help..........................................................................................................................27 12 Appendix 1. Valves included in Nelprof..................................................................27 13 Appendix 2. Nelprof load factor for rotary control valves.......................................27 14 Appendix 3. General control valve selection guidelines..........................................28 15 Cavitation noise level is high...................................................................................29 16 Control torque of the actuator is too small...............................................................29 17 Flow marginal is large..............................................................................................29 18 Flow marginal is small.............................................................................................30 19 Flow velocity in valve inlet port is high...................................................................30 20 Flow velocity in valve outlet port is high.................................................................30 21 Installed flow characteristics have not been analysed..............................................31 22 Maximum gain within the control range is high......................................................31 23 Minimum gain within the control range is small.....................................................32 24 Noise level is high....................................................................................................32 25 Opening or closing torque of the actuator is too small............................................32 26 Opening or closing torque with maxi dp is too high................................................33 27 Output thrust of the actuator is too small.................................................................33 28 Pressure is too high for the valve size......................................................................33 29 Ratio of maximum and minimum gain within the control range is high.................33 30 Supply pressure of the instrumentation air to the actuator is insufficient................34 31 Torque in control position with control dp is too high.............................................34 32 Valve is in flashing flow conditions.........................................................................34

33 Valve nominal size is larger than pipeline nominal size..........................................34 34 Valve nominal size is small compared to pipeline nominal size..............................34 35 Valve opening with maximum required capacity is high.........................................35 36 Valve opening with maximum required capacity is low..........................................35 37 Valve opening with minimum required capacity is low..........................................35 38 Valve shaft diameter is smaller than actuator hole..................................................36 39 Valve shaft diameter is too big to fit into the actuator hole.....................................36 40 Valve does not have enough capacity......................................................................36 41 Pressure is too high for the valve type.....................................................................36 42 Cavitation intensity is high.......................................................................................37

1 NELPROF 6.0 USERS GUIDE

1.1 General
1.1.1 Introduction

Welcome to the Metso Valve Sizing and Selection program Nelprof Version 6.0. Nelprof Version 6.0 is a valve selection expert system for Control, On-off and ESD valves. In addition to the calculation equations, it also includes expertise in the interpretation of results. It analyses selections and gives selection advice for control valves. Version 6.0 includes the technical selection from flow and control point of view a new module for actuator selection for On-off valves and SIL (safety integrity level) calculations. Control performance criteria, such as installed flow characteristics, cavitation and noise, form the basis for selection. Additional features are helping in the selections in the new version. However, one may find information about wide range of issues in literature presented along with the sizing program. The new features of Version 6.0 are:

On-off calculation module SIL and PFD (probability to fail on demand) calculation tool for 1oo1 and 1oo1D valve assemblies Flexible export with adapters to Metso datasheet generator (For Metso users) Control Valve Sizing Coefficients book updated

This Users Guide is specifically edited to Nelprof version 6.0. Wherever the reference is made to Nelprof in this Users Guide, Nelprof 6.0 is referred to.
1.1.2 Selection limitations

Selection is limited to flow, control and torque requirements regarding control and on-off valves valves. The user shall check the following aspects of selection separately:

Pressure, temperature limitations Pressure drop limitations (mechanical strength) Materials suitability Constructions suitability Available valve-actuator connections Commercial aspects

Checking of the valve construction (i.e. bearings, seats, gland backings) suitability, and in the case of uncommon materials also the valve body, is left to the user.

SIL calculation tool is intended to be used in the quotation phase only and does not correspond to and cannot be used instead of calculations made engineering department nominated expert.
1.1.3 System requirements

The Nelprof 6.0 is intended for use on Microsoft Windows XP, Vista, and 7 operating systems running on the Intel Architecture platform, with the disc space requirement of about 300 Mb.
1.1.4 Useful Windows commands

Following mouse and keyboard functions used in Windows helps to work with Nelprof 6.0 as well: Using the mouse - Use the mouse to point and the left mouse button to select. A single mouse click usually selects an item from the list box and only in some cases can you double click to select an item from the list and close the current window. Pressing the right mouse button causes a popup menu (if one exists) to appear. Start the program by double clicking the program icon. Using the keyboard - For some functions you can also use the fast key commands, e.g. Ctrl + item letter. Enter Move to next field/row/column (in input grid) Tab Move to the next field/column Shift + Tab Move to previous field/column Esc In an input window means cancel

Some Nelprof 6.0 keyboard commands: Arrows/Tab Ctrl + S Ctrl + R Ctrl + T Ctrl + I Delete Ctrl + F Ctrl + P Ctrl + X Ctrl + C Ctrl + V Ctrl + D Move in the input grid Saves the selected item an it's sub items Adds a new area tag in the tree Adds a new control tag in the tree Adds a new control sizing in the tree Deletes the selected item(s) Opens the find tag dialog Prints the sizing(s) Cut Copy Paste Duplicate

For more information about Windows refer to the Windows Users Guide or start the Windows Tutorial from the start Help menu.

2 Introduction to Nelprof Control and On-off calculation

2.1 Starting Nelprof Start Nelprof by double clicking on the Nelprof icon or by clicking the Nelprof 6.0 icon in the start menu or on the desktop. A disclaimer notice appears on the screen. Click OK to accept the disclaimer notice. The main Nelprof window appears on the screen. 2.2 Step 1 - Identification creation When the program is first time used, it asks for your first name and last name. This information is used to create unique identification of your projects. This information can be later changed when needed in Preferences - User Preferences menu. 2.3 Step 2 - Creating Project and entering Project properties To start the sizing you have to first create a Project. You can do this by selecting File|New Project from the menu. New project appears in the project tree. Click the text Project in the tree and you see the Project Info screen. Enter the data to the fields. Part of this information will show up in the printouts. Under project, there is always at least one area. One project can cover several areas, depending on actual plant/project. All new created project trees have by default a structure which includes one area under the project, one tag under the area and one sizing under the tag. The tree can be expanded with the following steps 2.4 Step 3 - Creating Area and entering Area properties Under each project you can have several Areas. Each area can represent a part or a section of a project. More areas can be created by selecting Create|Add Area from the menu or by clicking the Add Area button from the tool bar. When you add a new area, it will be empty and a tag or tags need to be created separately to proceed to a calculation. Area name can be changed from the Area field name menu which appears when you click the text Area at the project tree. 2.4 Step 4 - Creating Tag and entering Tag properties After you have created a project with an area, you can create a Tag. This can be done by selecting Create|Add Tag from the menu or by clicking the Add Tag button from the tool bar. When you add tag, one sizing will appear automatically under the tag. Select Create| Add On-off Tag with a red valve icon to create On-off tag and select Create|Add Control Tag to create Control tag with a light blue valve icon.

New Tag appears accordingly in the project tree and by clicking the Tag text you see the Tag Properties screen. Enter the tag details to the corresponding fields when available. Part of this information will appear in the printouts. 2.5 Step 5 - Entering Input data Select the sizing that you created in the Step 4 (See Step 10 for adding more sizing calculations under each tag). To enter input data you must first select the process fluid phase: liquid, water, gas, steam, pulp or 2-phase. The corresponding input screen appears and you can fill in the information concerning piping, fluid, flow, pressures, valve and actuator. If you do not want to size an actuator uncheck the Actuator sizing checkbox. You can proceed from a field to another by pressing Tab, Enter, Arrow or by using the mouse. With right mouse button you can copy column, clear column or copy field when cursor is on data entry area. The program will warn you if information is missing or if values are out of limits. 2.6 Step 6 - Selection After all required input data have been entered, selection is performed by clicking the button CALCULATE. When using automatic valve size selection, the size is selected according to the flow and control requirements. Openings, noise, flow velocity, flow characteristics, cavitation etc. are evaluated as the size selection criteria. Specify the valve size when entering input data to perform manual valve sizing. Actuator size is selected according to opening, closing and control torque. For control the actuator is sized to obtain a certain amount of extra power for good control performance. Specify the actuator size and for spring return actuators also the spring rating to perform manual selection. For On-off sizing the automatic actuator size is selected according to BTO (break to open) and ETC (end to close) requirements including the recommended actuator sizing safety factor. 2.7 Step 7 Analysis After calculation the valves short code and size appears in the Result box. The actual analysis can be performed through the tabs located under the tool bar. The following analysis functions are available for control valve sizing: Sizing Valve and actuator sizing with results, e.g. openings, noise, required operational torques etc.

Notes and warnings VDMA Noise level as a function of valve travel for the installed valve for control valves Notes and warnings regarding the selected valve and actuator for given process data for control valves Own remarks field

Characteristic curves Inherent charaterisctis: Intrinsic Cv curve of the selected valve Installed flow characteristic: Characteristic flow as a function of valve travel installed in a process Installed gain: Gain as a function of characteristic mass flow installed in a process Installed pressure level: Upstream and downstream pressures as functions of valve travel.

2.8 Step 8 - Saving and loading data Data is saved as projects. One project is one XML file which should be named when saving the file. You can save all projects by selecting File|Save All from the menu or by clicking the Save all -button in the toolbar. You can save data of certain project by selecting the project from the tree and clicking the save button on the toolbar or by selecting File|Save. This will save data of that project and all its sub-items. The default path for project files is presented in Preferences-User preferences and it can be changed to whatever user wants. To import sizing data from other data formats like csv, select File|Import/Export from the menu. Adapter Window is opened and usage is explained in different chapter. 2.9 Step 9 - Printing Printout can have one project, with multiple areas, tags and sizings. With different language properties files, different language versions of the printout can be made. User must select printable objects from the project tree. Several sizing sheets can be printed at once. Mark the sizings you wish to print and select File|Print from the menu or by clicking the Print button from the tool bar.

Figure 1. Sizing selections for printing Language selection and selection of printed objects is performed after print command has been pressed. English is the default language. Optional languages are available for the control valve sizing only.

Figure 2. Printing selection options If you have problems in printing, make sure all connections are correctly in place and use the printer setup to define the printer and printer defaults. 2.10 Step 10 - New calculation and exiting the program New calculation can be created by pressing the Add sizing button from the tool bar or from menu. Select Create|Add Control sizing to create a Control sizing and Create|Add Onoff sizing to create an On-off sizing. If you do not want to save the old sizing you can type over the old input data and re-calculate. To exit Nelprof 6.0, select File|Exit from the menu. If any data have been changed, Nelprof will ask if you want to save this data before exiting.

3 The Project Tree

In the project tree you can add, rename, delete, copy, cut, find and print tree items. You can also sort tags in a project by their creation date or name. The Project tree is located on the left-hand side of the user interface. Right mouse button brings a popup menu onto screen.

Figure 3. The Project Tree

Each file represents a project. Under that there are areas, tags and sizings. One project can include several areas, one area can include several Tags. Every tag can include several sizings.

To view Project info, click the project name. To view Area info, click the area name. To view Tag info, click the Tag name. To view Sizing, click the sizing name. After this you can see the sizing input/output data on your Nelprof main window. To Create a new project, area, tag or sizing, select the place from the project tree where you want to place the new object and choose File|Add Project, Create|Add Area, Create| Add Tag or Create|Add Sizing from the menu. To Rename a project, area or tag, use the properties window of each object. To Delete a project, area, tag or sizing, select the object(s) that you want to delete with right mouse button and press delete button. The object(s) will be deleted permanently. To Print a sizing, just select it by checking the box on the left side of the sizing name from the Project tree and click the print button in the toolbar. If you want to select more than one Area, Tag or Sizing, check them all. Note that by checking the area, all objects of an area will be selected.

4 Control valve sizing and analysis

Automatic valve size selection is based only on flow and control. Selection considers topics such as valve opening, noise level, flow velocities, cavitation for liquids and installed flow characteristics. The program does not consider special requirements of fluids or processes. It is very important to study the suitability of the valve materials and construction separately for each application. To size a valve, follow the steps shown in chapter 2. A more detailed description of sizing in different fluid phases is given in this chapter. 4.1 Liquid and water sizing
4.1.1 Input data for liquid and water sizing

You can select liquid or water sizing by pressing the appropriate button on the input data window. When sizing for liquid and water flow you enter data as shown in the next figure. Certain information will appear automatically.

Figure 4. Input data for liquid and water sizing

Changing the units, see chapter 5 on User settings. (1) Process fluid selection. A selection of fluids is available in upper field. Free description of the fluid can be entered in the lower field. (2) Spec grav. Specific gravity (not included in water sizing). Enter Spec gravity. Or leave this field empty and enter Density. If neither is entered, the specific gravity for water is used. (3) Density (not included in water sizing). Enter Density. Or leave this field empty and enter Spec gravity. If neither is entered, the specific gravity for water is used in the calculation. (4) Crit press. Critical pressure. If not entered, the critical pressure for water is used in the calculation. (5) Viscosity. If entered, Nelprof will check for non-turbulent flow conditions and correct the calculations if necessary. See more details in the Flow Control Manual. (6) Special service req. By default service is Normal. If known that process in question has special requirement is known to cause friction increase due to the application or fluid other selection can be used accordingly. Other selection can affect to the recommended actuator sizing safety factor. (7) DPm. The process pressure ratio factor. This is needed for installed flow characteristics and gain calculation in one flow case scenario. DPm defines the portion of the total system pressure losses as taken by the control valve at maximum

flow rate. The default value for liquid flow is 0.3 (30% of total system pressure loss is taken by the valve, 70% by the piping and pipe components). For Finetrol valve default value is 0.5. DPm is not needed if two or more flow cases are given. Look for more details in the Flow Control Manual. (8) Design P. Max design pressure condition for the Tag. Input value for documentation. Value does not automatically affect to the valve selection within the program. Manual considerations in the valve selection must be made according to the requirements. (9) Design Tmax. Max design temperature for the Tag. Input value for documentation. Value does not automatically affect to the valve selection within the program. Manual considerations in the valve selection must be made according to the requirements (10) Design Tmin. Min design temperature for the Tag. Input value for documentation. Value does not automatically affect to the valve selection within the program. Manual considerations in the valve selection must be made according to the requirements (11) Inlet dia. Nominal diameter of the upstream pipeline. (12) Outlet dia. If not entered, the nominal diameter of the downstream pipeline is assumed to be the same as the inlet diameter. (13) Thickness. Pipe Wall Thickness. Enter either Thickness or Schedule. (14) Schedule. Piping schedule number. Enter either Thickness or Schedule. If neither is entered, then Sch 40 will appear as the default value. Needed only for noise calculation. (15) Flow Rate. Flow rates for four different flow conditions can be entered. (16) Inlet Temp. Temperature at upstream conditions. (17) Inlet Press. Pressure at upstream conditions. (18) Press Diff. Differential pressure across the valve with corresponding flow rate. The value must be lower than the given upstream pressure. Enter either pressure differential or outlet pressure. (19) Outlet press. Outlet pressure of the valve. Enter either pressure differential or outlet pressure. (20)

Vap Press. Vapour pressure. Provided automatically for liquids included in Nelprof. The value that Nelprof provides can be replaced by the users own value by typing over the default value. Value entered is vapour pressure of the liquid at upstream temperatures. A careful search for accurate vapour pressure is recommended, as this information is needed in cavitation and flashing flow calculations. (21) Valve. By pressing this button you can open a valve type list and selection dialog. Valve type can be selected from here or by using fields 18, 19 and 20. (22) Type. Select valve type from the list. (23) Press rating. Pressure rating required. Select rating from the list. If you select All, valves available in all ratings are listed in Code column. (24) Code. Select valve code from the list. (25) Size. Valve nominal size/reduction. Will be automatically selected when autom appears instead of size.
4.1.2 Results for liquid and water sizing

Figure 5. Results for liquid and water sizing

Max capacity Req capacity Travel

Maximum flow capacity of the chosen control valve, taking into account piping reducers. Calculated capacity needed for flow conditions specified in the same column.

Opening as a percentage of full travel, excluding initial opening. The initial opening is the travel before the flow starts. Opening Opening in degrees for rotary valves, including initial opening. Noise Predicted sound pressure level based on the VDMA 24422 (May 1979) or enhanced IEC 60534-8-4 standard. A high noise level for liquid flow is a good indication of a high cavitation level. Q-Trim or similar low-recovery valves are

recommended in case of high noise levels. The maximum recommended hydrodynamic noise levels in valves calculated with non-insulated schedule 40 piping are: - 80 dB(A) for valve sizes up to 80 mm (3") size, - 85 dB(A) for valve sizes 100-150 mm (4"-6") size, - 90 dB(A) for valve sizes 200-350 mm (8"-14") size, - 95 dB(A) for valve sizes 400 mm (16") and larger size.

The figures are given considering the valve operation. Workplace safety regulations, and end-user specifications etc. may dictate other maximum values. Flow velocity Flow velocity at the valve inlet. The maximum recommended valve inlet velocities are as follows: a) Continuous duty - Butterfly valves 7 m/s, 23 ft/s. - Cage-guided globe valves 15 m/s, 50 ft/s. - All other valves 10 m/s, 32 ft/s. b) Infrequent Duty - Butterfly valves 8.5 m/s, 27 ft/s. - Cage-guided globe valves 18 m/s, 60 ft/s. - All other valves 12 m/s, 39 ft/s. Terminal Often referred to as Critical pressure drop. Whenever the differential pressure is dp higher than the terminal pressure drop the valve will experience high intensities of cavitation. The use of Q-Trim or similar is recommended to avoid cavitation problems. In cases where conditions result in flashing, the terminal pressure drop is not significant. Then, word "flashing" will appear in this field. Flow Control Manual offers more information of the meaning of terminal pressure drop. Fl coeff The pressure recovery factor of the valve with this particular opening. 4.2 Gas and steam sizing
4.2.1 Input data for gas and steam sizing

When sizing for gas and steam flow the data should be entered as shown in the next figure. Some of the information will appear automatically.

Figure 6. Input data for gas and steam flow Changing the units, see chapter 5 User settings. (1) Process fluid selection. A selection of fluids is available in upper field. Free description of the fluid can be entered in the lower field. (2) Spec grav. Specific gravity. Enter Specific gravity. Enter either Spec gravity or Mol Weight. (3) Mol weight. Molecular weight (not included in steam sizing). Enter either Spec gravity or Mol Weight. If neither is entered, the upstream density must be entered instead of compressibility in process data area. (4) Spec heats. Ratio of Specific Heats. If not entered, the value 1.4 for air is used. For steam sizing 1.3 will appear automatically. (5) Special service req. By default service is Normal. If known that process in question has special requirement is known to cause friction increase due to the application or fluid other selection can be used accordingly. Other selection can affect to the recommended actuator sizing safety factor. (6) DPm. The process pressure ratio factor. This is needed for installed flow characteristics and gain calculation in one flow case scenario. DPm defines the portion of the total system pressure losses as taken by the control valve at maximum flow rate. The default value for liquid flow is 0.3 (30% of total system pressure loss is taken by the valve, 70% by the piping and pipe components). For Finetrol valve default value is 0.5. DPm is not needed if two or more flow cases are given. Look for more details in the Flow Control Manual. (7) Design P. Max design pressure condition for the Tag. Input value for documentation. Value does not automatically affect to the valve selection within the

program. Manual considerations in the valve selection must be made according to the requirements. (8) Design Tmax. Max design temperature for the Tag. Input value for documentation. Value does not automatically affect to the valve selection within the program. Manual considerations in the valve selection must be made according to the requirements (9) Design Tmin. Min design temperature for the Tag. Input value for documentation. Value does not automatically affect to the valve selection within the program. Manual considerations in the valve selection must be made according to the requirements (10) Inlet dia. Nominal diameter of the upstream pipeline. (11) Outlet dia. If not entered, the nominal diameter of the downstream pipeline is assumed to be the same as the inlet diameter. (12) Thickness. Pipe Wall Thickness. Enter either Thickness or Schedule. (13) Schedule. Piping schedule number. Enter either Thickness or Schedule. If neither is entered, then Sch 40 will appear as the default value. Needed only for noise calculation. (14) Flow Rate. Flow rates for four different flow conditions can be entered. (15) Inlet Temp. Temperature at upstream conditions. (16) nlet Press. Pressure at upstream conditions. (17) Press Diff. Differential pressure across the valve with corresponding flow rate. The value must be lower than the given upstream pressure. Enter either pressure difference or outlet pressure. (18) Outlet press. Outlet pressure of the valve. Enter either press difference or outlet press. (19) Compress or Upstream Density. Compressibility is provided automatically for the gases included in Nelprof. The value that Nelprof provides can be replaced by the users own value by typing over the default value. Upstream density is provided automatically in steam sizing. (20) Valve. By pressing this button you can open a valve type selection dialog. Valve type can be selected from here or by using the fields 18, 19 and 20. (21) Type. Select valve type from the list. (22)

Press rating. Pressure rating required. Select rating from the list. (23) Code. Select valve code from the list. (24) Size. Valve nominal size/reduction. Will be automatically selected when autom appears instead of size.
4.2.2 Results for gas and steam flow

Figure 7. Results for gas and steam sizing Max capacity Req capacity Travel Maximum flow capacity of the chosen control valve, taking into account piping reducers. Calculated capacity needed for flow conditions specified in the same column.

Opening as a percentage of full travel, excluding the initial opening. The initial opening is the travel before the flow starts. Opening Opening in degrees for rotary valves, including the initial opening. Noise Predicted sound pressure level based on the VDMA 24422 (May 1979) or IEC 60534-8-3 standard. In most countries 85 dB(A) is the maximum permitted noise level. A noise level higher than 110 dB(A) will subject piping and equipment to possible vibration damage. Q-Trim or similar low-noise valves are recommended to reduce noise. Also, downstream resistors such as diffusers and A-plates can be used to reduce noise. Flow Flow velocity at the valve outlet. The maximum recommended valve outlet velocity velocities are as follows: - 0.5 Mach for continuous control, - 0.7 Mach for infrequent duty, e.g. flaring and venting. Xt coeff Valve pressure drop ratio factor with this particular opening. Defined according to standards IEC60534 and ISA S75. 4.3 Pulp stock sizing In pulp flow sizing the input information is almost the same as in liquid flow sizing. The difference is in fluid description, in which you specify the stock type and also consistency.
4.3.1 Input data for Pulp Stock Sizing

When sizing for pulp flow the data is entered as shown in the next figure. Compared with water sizing, the differences are in fluid description and consistency.

Figure 8. Input data for Pulp Stock Sizing Changing the units, see chapter 5 User settings. (1) Process fluid selection. Free description of the fluid can be entered in the lower line. (2) Consist %. The consistency of the pulp stock. More details of calculation are given in the Flow Control Manual. (3) Crit press. Critical pressure. If not entered, the critical pressure for water is used in the calculation. (4) Special service req. By default service is Normal. If known that process in question has special requirement is known to cause friction increase due to the application or fluid other selection can be used accordingly. Other selection can affect to the recommended actuator sizing safety factor. (5) DPm. The process pressure ratio factor. This is needed for installed flow characteristics and gain calculation in one flow case scenario. DPm defines the portion of the total system pressure losses as taken by the control valve at maximum flow rate. The default value for liquid flow is 0.3 (30% of total system pressure loss is taken by the valve, 70% by the piping and pipe components). For Finetrol valve default value is 0.5. DPm is not needed if two or more flow cases are given. Look for more details in the Flow Control Manual. (6) Design P. Max design pressure condition for the Tag. Input value for documentation. Value does not automatically affect to the valve selection within the

program. Manual considerations in the valve selection must be made according to the requirements. (7) Design Tmax. Max design temperature for the Tag. Input value for documentation. Value does not automatically affect to the valve selection within the program. Manual considerations in the valve selection must be made according to the requirements (8) Design Tmin. Min design temperature for the Tag. Input value for documentation. Value does not automatically affect to the valve selection within the program. Manual considerations in the valve selection must be made according to the requirements (9) Inlet dia. Nominal diameter of the upstream pipeline. (10) Outlet dia. If not entered, the nominal diameter of the downstream pipeline is assumed to be the same as the inlet diameter. (11) Thickness. Pipe Wall Thickness. Enter either Thickness or Schedule. (12) Schedule. Piping schedule number. Enter either Thickness or Schedule. If neither is entered, then Sch 40 will appear as the default value. Needed only for noise calculation. (13) Flow Rate. Flow rates for four different flow conditions can be entered. (14) Inlet Temp. Temperature at upstream conditions. (15) Inlet Press. Pressure at upstream conditions. (16) Press Diff. Differential pressure across the valve with corresponding flow rate. The value must be lower than the given upstream pressure. Enter either press differential or outlet press. (17) Outlet press. Outlet pressure of the valve. Enter either pressure differential or outlet pressure. (18) Valve. By pressing this button you can open a valve type selection dialog. Valve type can be selected from here or by using the fields 18, 19 and 20. (19) Type. Select valve type from the list. (20) Press rating. Pressure rating required. Select rating from the list. (21) Code. Select valve code from the list. (22)

Size. Valve nominal size/reduction. Will be automatically selected when autom appears instead of size.
4.3.2 Results for Pulp sizing

Figure 9. Results for Pulp sizing

Max capacity Req capacity Travel

Maximum flow capacity of the chosen control valve, taking into account piping reducers. Calculated capacity needed for flow conditions specified in the same column.

Opening as a percentage of full travel, excluding the initial opening. The initial opening is the area where the seat and closing member overlap. Opening Opening in degrees for rotary valves, including the initial opening. Noise Predicted sound pressure level based on the VDMA 24422 (May 1979) or enhanced IEC 60534-8-4 standard. A high noise level for liquid flow is a good indication of a high cavitation level. Q-Trim, Flash-Flo or similar low-recovery valves are recommended in case of high noise levels. The maximum recommended hydrodynamic noise levels in valves calculated with non-insulated schedule 40 piping are as follows: - 80 dB(A) for valve sizes up to 80 mm (3") size, - 85 dB(A) for valve sizes 100-150 mm (4"-6") size, - 90 dB(A) for valve sizes 200-350 mm (8"-14") size, - 95 dB(A) for valve sizes 400 mm (16") and larger size. Note: Q-trim can be used up to 4% pulp consistency.

The figures are given considering the valve operation. Workplace safety regulations, enduser specifications etc. may dictate other maximum values. Flow velocity Flow velocity at valve inlet. The maximum recommended valve inlet velocities are as follows:

a) Continuous duty - Butterfly valves 7 m/s, 23 ft/s. - Cage-guided globe valves 15 m/s, 50 ft/s. - All other valves 10 m/s, 32 ft/s. b) Infrequent Duty - Butterfly valves 8.5 m/s, 27 ft/s. - Cage-guided globe valves 18 m/s, 60 ft/s. - All other valves 12 m/s, 39 ft/s. Terminal Whenever the differential pressure is higher than the terminal pressure drop the dp valve will experience high intensities of cavitation. The use of Q-Trim or FlashFlo type trims is recommended to avoid cavitation problems. In cases where conditions result in flashing, the terminal pressure drop is not significant. Then, word "flashing" will appear in this field. Flow Control Manual offers more information of the meaning of terminal pressure drop. Fl coeff The pressure recovery factor of the valve with this particular opening. 4.4 2-phase flow sizing This calculation allows you to size valves for liquid + gas and liquid + vapour mixtures. Consider the results of liquid + vapour calculation very carefully. The calculation methods are the best available, but the behaviour of a saturated liquid + vapour mixture is very difficult to predict. The method used provides very accurate results when the percentage of vapour in the fluid is high. The error increases as the percentage of vapour in the fluid decreases. You can find more detailed information on calculation in the Flow Control Manual.
4.4.1 Input data for 2-phase flow sizing

When sizing for 2-phase flow you can enter data as shown in the next figure.

Figure 10. Input data for 2-phase flow sizing

Changing the units, see chapter 5 User settings. (1) Process fluid selection, liquid. (2) Process fluid selection, gas or vapour. (3) L spec grav. Specific gravity of the liquid component. Enter Spec gravity or leave this out and enter Density. (4) Density. Enter Density. Or leave this out and enter Spec gravity. If neither is entered, the specific gravity for water is used in the calculation. (5) Crit press. Critical pressure of the liquid. If not entered, the critical pressure for water is used in the calculation. (6) G spec grav. Specific gravity of the gaseous component. Enter either Specific gravity or Density. (7) Mol weight. Enter either Specific gravity or Density. If neither is entered, the upstream density must be entered instead of compressibility in process data area. (8) Spec heats. Ratio of Specific Heats. If not entered, the value of air is used. For steam sizing 1.3 will appear automatically. (9) Special service req. By default service is Normal. If known that process in question has special requirement is known to cause friction increase due to the application or fluid other selection can be used accordingly. Other selection can affect to the recommended actuator sizing safety factor. (10) DPm. The process pressure ratio factor. This is needed for installed flow characteristics and gain calculation in one flow case scenario. DPm defines the portion of the total system pressure losses as taken by the control valve at maximum flow rate. The default value for liquid flow is 0.3 (30% of total system pressure loss is taken by the valve, 70% by the piping and pipe components). For Finetrol valve default value is 0.5. DPm is not needed if two or more flow cases are given. Look for more details in the Flow Control Manual. (11) Design P. Max design pressure condition for the Tag. Input value for documentation. Value does not automatically affect to the valve selection within the program. Manual considerations in the valve selection must be made according to the requirements. (12) Design Tmax. Max design temperature for the Tag. Input value for documentation. Value does not automatically affect to the valve selection within the program.

Manual considerations in the valve selection must be made according to the requirements (13) Design Tmin. Min design temperature for the Tag. Input value for documentation. Value does not automatically affect to the valve selection within the program. Manual considerations in the valve selection must be made according to the requirements (14) Inlet dia. Nominal diameter of the upstream pipeline. (15) Outlet dia. If not entered, the nominal diameter of the downstream pipeline is assumed to be the same as the inlet diameter. (16) Thickness. Pipe Wall Thickness. Enter either Thickness or Schedule. (17) Schedule. Piping schedule number. Enter either Thickness or Schedule. If neither is entered, then Sch 40 will appear as the default value. Needed only for noise calculation. (18) Gas Flow. The flow rate of the gaseous component for four different flow conditions can be entered. (19) Liq flow. The flow rates of the liquid component for four different flow conditions can be entered. (20) Inlet Temp. Temperature at upstream conditions. (21) Inlet Press. Pressure at upstream conditions. (22) Press Diff. Differential pressure across the valve with corresponding flow rate. The value must be lower than the given upstream pressure. Enter either pressure differential or outlet pressure. (23) Outlet press. Outlet pressure of the valve. Enter either pressure differential or outlet pressure. (24) Liq vap press. Liquid vapour pressure. Provided automatically for liquids included in Nelprof. The value that Nelprof provides can be replaced by the users own value by typing over the default value. Vapour pressure of the liquid at upstream temperatures. A careful search for accurate vapour pressure is recommended, as this information is needed in cavitation and flashing flow calculations. (25) Gas comp or Gas Upstream. Compressibility or density of the gas component at upstream conditions. Compressibility is specified when either the specific gravity or molecular weight is specified. A typical compressibility value is 1.0. Upstream density must be given if specific gravity or molecular weight is not known. (26)

Valve. By pressing this button you can open a valve type selection dialog. Valve type can be selected from here or by using fields 18, 19 and 20. (27) Type. Select valve type from the list. (28) Press rating. Pressure rating required. Select rating from the list. (29) Code. Select valve code from the list. (30) Size. Valve nominal size/reduction. Will be automatically selected when autom appears instead of size.
4.4.2 Results for 2-phase sizing

Figure 11. Results for 2-phase sizing Max capacity Req capacity Travel Maximum flow capacity of the chosen control valve, taking into account piping reducers. Calculated capacity needed for flow conditions specified in the same column. Opening as a percentage of full travel, excluding the initial opening. The initial opening is the area where the seat and closing member overlap. Opening in degrees for rotary valves, including the initial opening. The average density of the liquid + gas mixture.

Opening Eff density Terminal Often referred to as Critical pressure drop. Applicable for the liquid component. dp Whenever the differential pressure is higher than the terminal pressure drop the valve will experience high intensities of cavitation. The use of Q-Trim or similar trims is recommended to avoid cavitation problems. In cases where conditions result in flashing, the terminal pressure drop is not significant. 4.5 Actuator sizing If you want to size a valve without an actuator, uncheck the Actuator sizing selection in the input data screen. Actuator sizing is based on operation in control as well as the opening/closing of the valve. In control, the valve torque/thrust is calculated according to the given information on flow

and pressure. In closing/opening, valve torque/thrust is calculated according to dp Shutoff. Valve-required torque is calculated according to actual dimensions and friction coefficients, dynamic flow-induced forces are also considered. The valve type and size as well as the flow conditions are required for actuator sizing.
4.5.1 Actuator sizing input data for rotary valves

Figure 12. Actuator sizing input data for rotary valves Seat Select valve seat type from the list. Gland Select gland packing type from the list. pack Bearings Select valve bearing type from the list. This information is not required for globe valves. Safety Customer safety factor. The actuator size selection is depending on the selected factor safety. The default value on the screen for customer value is 1.0. Minimum recommended safety factor by Metso is 1.1 for Open and Close and about 1.6 for control open/close positions. DP Maximum shutoff pressure against which the valve must open and close. shutoff Actuator By pressing this button you can open an actuator type selection dialog. Actuator type can be selected from here or by using field Code. Code Select actuator code from the list. Size Actuator size code. Will be automatically selected when Autom appears instead of size. Supply Supply pressure of the instrumentation air to the actuator. This affects selection press of the spring for single-acting actuators. Spring Spring rate or stiffness of the spring. Expressed as nominal pressure of the rate spring. Select a spring rate equal or lower than the available supply pressure. Spring rate cannot be selected for linear actuators. Select the actuator spring when selecting the actuator size manually. The actuator spring rate is expressed as the nominal spring rate pressure: e.g. B1J, size 20, has three different spring rate options: 3 barG corresponding to BJK20, 4 barG corresponding to BJ20 and 5.5 barG corresponding to BJV20. In automatic sizing the program selects the spring rate according to the available supply pressure.
4.5.2 Actuator sizing results for rotary valves

Figure 13. Actuator sizing results for rotary valves To open Opening LF Control open Ctrl open LF Torque required to begin opening the valve. Breakaway torque for eccentric valves and friction torque for concentric valves. Calculated with dp Shutoff. Equals to BTO (break to open) torque with On-off calculation. Opening load factor. Load factor is the required torque divided by the available torque. A value of 62 means that 62% of the torque given by the actuator output torque is needed to open the valve. The opening load factor should be below 90 to allow some safety margin in the selection. Torque required in modulating the control when increasing opening. Equals the friction torque + dynamic torque. Dynamic torque tends to close or open the valve, depending on the type of valve. Calculated with control flow conditions. Control to open load factor. Load factor is the required torque divided by the available torque. A value of 28 means that 28% of the actuator output torque is needed to slightly increase the opening of the valve. The control to open load factor should be below 60 for high-friction valves; for low-friction valves it can be slightly higher. Extra torque in modulating the control is needed to allow smooth, stiction-free control. Torque required in modulating the control when decreasing opening. Equals the friction torque - dynamic torque. Dynamic torque tends to close or open the valve, depending on the type of the valve. Calculated with control flow conditions. Control to open load factor. Load factor is the required torque divided by the available torque. A value of 25 means that 25% of the actuator output torque is needed to slightly decrease the opening of the valve. The control to close load factor should be below 60 for high-friction valves; for low-friction valves it can be slightly higher. Extra torque in modulating the control is needed to allow smooth stiction-free control. The torque required to fully close the valve. For eccentric valves this is the torque needed to attain tightness; for concentric valves it is the friction torque. Calculated with dp Shutoff. Equals to ETC (end to close) torque with On-off calculation. Closing load factor. Load factor is the required torque divided by the available torque. A value of 62 means that 62% of the torque given by the actuator output torque is needed to close the valve. The closing load factor should be below 90 to allow some safety margin in the selection.

Control Close Ctrl close LF

To Close

Closing LF

4.6 Sizing Resistors i.e. plates and diffusers To do resistor sizing, you have to calculate the valve first selecting size manually in the Size field. Automatic valve size selection is not available for diffuser and plate sizing. Please note also that resistor sizing is not available for 2-phase flow. Then, to define a resistor, click the Resistors button.
4.6.1 Defining resistors for liquid flow

After you have clicked the Resistors button the following window appears:

Figure 14. Liquid resistor defining window When selecting one of the plate options available you also specify the required size as well as the New Valve dp. The new valve pressure differential defines that portion of the original pressure differential that is allocated to the control valve. The remainder is for the plate. The plate-effective flow area is defined according to this information. The permitted sizes for plates are the sizes between the nominal valve diameter and the downstream pipe

diameter. For liquid flow, select the following options: The Liquid Baffle Plate is a flat baffle plate with straight holes. The hole number and diameter are altered case by case to fit the specified conditions exactly. The baffle plate is usually installed downstream of the valve. Orifice Plate, Downstream. The orifice plate is a simple single-hole plate used in flow rate measurement. When installed downstream it increases the downstream pressure of the valve itself. Orifice Plate, Upstream. When installed upstream it decreases the upstream pressure of the control valve. After you have specified the resistor, press the OK button. After this the valve can be sized by pressing the Calculate button on the sizing screen. If you want to size the valve without the resistor, just uncheck the Resistors check box.
4.6.2 Results for a valve with a resistor for a liquid flow

When you size a valve with a resistor there will be some additional information on the results.

Figure 15. Results for a valve with a resistor for a liquid flow The max capacity, req capacity, travel, opening, noise, flow velocity terminal dp and Fl coeff are the same as for normal liquid sizing (see results for liquid and water sizing).

Plate area New dp

Plate area is the plates effective flow area, i.e., portion of the hole/holes from the whole plate. New dp is the valve new dp. When the resistor is selected, part of the pressure drop designated to the valve will go to the resistor. New dp will show how much is left

for the valve.

4.6.3 Defining resistors for gaseous flow

After you have clicked the Resistors button the following window appears:

Figure 16. Gas resistor defining window When selecting one of the plate options available you also specify the required size or the New Valve dp. The new valve pressure differential defines that portion of the original pressure differential that is allocated to the control valve. The remainder is for the plate. The plate-effective flow area is defined according to this information. The permitted sizes for plates are the sizes between the nominal valve diameter and the downstream pipe diameter. For gaseous flow, select the following options: 1-Stage Diffuser. The 1-stage diffuser is always installed downstream of the valve. You must also specify the New Valve dp. The new valve pressure differential defines that portion of the original pressure differential allocated to the control valve, the remainder is for the diffuser. A default value is always shown. Diffusers are fabricated case-by-case so that the New valve dp affects the design of the diffuser tube. The 2-stage diffuser gives lower noise levels than a single-stage diffuser.

2-Stage

Diffuser. Attenuator The attenuator plate has specific hole geometry to achieve better noisePlate. reduction capability than that achieved with just simple straight holes. To make an attenuator plate sizing calculation, select the size of the plate. The permitted sizes are those between the nominal valve diameter and downstream pipe diameter. After you have specified the resistor, press the OK button. After this the valve can be sized by pressing the Calculate button on the sizing screen. If you want to size the valve without the resistor, just uncheck the Resistors check box.

4.6.4 Results for a valve with a resistor for a gaseous flow

When you size a valve with a resistor there will be some additional information in the results.

Figure 17. Results for a valve with a diffuser for gas flow Min outlet pipe New dp The minimum outlet pipe diameter for diffusers. New dp is the valve new dp. When the resistor is selected, part of the pressure drop designated to the valve will go to the resistor. New dp will show how much is left for the valve.

4.7 Comparing the results of two sizings The Comparison tab can be used to compare the sizing results of two sizing views. First select the sizing from the project tree that you want to compare. Then select the comparison tab. Now by clicking from the project tree you can select different sizings for comparison. See picture.

Figure 18. Comparing the two sizings After comparing the sizing views, you may compare the characteristic curves by selecting Characteristic Curves tab. 4.8 Characteristic curves The flow characteristics of an installed control valve are discussed in detail in the Flow Control Manual. The main principle is to approximate the static performance throughout the entire opening range for defined upstream and downstream pressure changes as functions of the flow rate. The pressure changes are calculated as second-degree

polynomials, if two or three flow cases are given. If only one flow case is given, the pressures are approximated with the DPm factor. There are certain situations in which Nelprof cannot reliably calculate the installed flow characteristic curves:

There are no suitable valves for the application. Two flow cases with the same flow rate Upstream pressure increases with increasing flow or downstream pressure decreases with increasing flow 2-phase flow

4.8.1 Characteristic curves

The Characteristic curves can be observed by selecting the Characteristic curves tab. See the picture below.

Figure 19. The characteristic curves

Inherent Flow Characteristics. The inherent flow characteristics is the relative Cv curve of the valve. The inherent flow characteristic is always available and can be printed even when the installed flow characteristic cannot. Installed Flow Characteristics. The installed flow characteristics is the relative flow rate through an installed valve. The installed flow characteristic describes the static performance of the valve under actual conditions and thus gives valuable prediction of valve performance. Installed Gain. Installed gain is the slope of the installed flow characteristic curve. With gain curve, valve controllability and accuracy under actual conditions can be established. Details on analysis can be found in the Flow Control Manual. Installed Pressure Level. The installed pressure level graph presents the upstream and downstream pressures as functions of the relative valve opening. These curves are defined by selection of the DPm factor, or in multiple-flow cases the pressures are fitted to flow data as second-degree polynomials.
4.8.2 Notes and warnings

The Noise curve and notes can be observed by selecting the Notes and warnings tab. See the picture below.

Figure 20. Installed Noise Curve, Notes and Warnings + Remarks Installed Noise. The installed noise curve gives the estimated VDMA noise levels throughout opening of the valve. Notes and Warnings:

Notes and warnings are shown for the selected valves. Both warnings and notes should be taken into account when the valve is selected. Warning is an indication of a potentially more severe problem than a note. Selecting a note or a warning with the mouse will open the explanation system. A short description of the note or warning background is included in the explanation system. The explanation comprises theory, problem and solutions sections. For some of the notes there are references to the Flow Control Manual. Clicking a reference once will open the Flow Control Manual at the corresponding page.

5 On-off valve sizing and analysis

On-off valve sizing tool is in practice intended for the calculation of correct size actuator. Automatic actuator size selection is based on valve required torque and selected actuator available output. The tool calculates the required torque at selected shutoff pressure difference. Calculation considers topics such as valve construction e.g. seat, bearing and packing type and material and also the differences of the actuator output at different travel. The program does not consider special requirements of fluids or processes. However a safety factor can be applied for the automatic actuator calculation to take into account these requirements. It is very important to study the suitability of the valve materials and construction separately for each application. To start a sizing, follow the steps shown in chapter 2. A more detailed description of sizing a On-off valve is given in this chapter. 5.1 Input data After you have created and opened the On-off calculation you should first select the phase by pressing the appropriate button on the input data window. Depending on the selected phase the fluid description box content varies the same way as above with the control calculation (see chapter 4).Certain information will appear automatically. Changing the units, see chapter 5 on User settings. (1) Process fluid selection. A selection of fluids is available in upper field. Free description of the fluid can be entered in the lower field. (2) L or G Spec grav. Specific gravity of the fluid (not included in water sizing). Enter Spec gravity. Or leave this field empty and enter Density for liquids and Molecular weight for gases. This field is optional for On-off calculations and used only for documentation purposes. (3) Density (only with liquid sizing). Enter Density. Or leave this field empty and enter Spec gravity. This field is optional for On-off calculations and used only for documentation purposes. (4) Crit press. Critical pressure. (only with liquid sizing). If not entered, the critical pressure for water is used in the calculation. This field is optional for On-off calculations and used only for documentation purposes. (5) Viscosity. (only with liquid sizing). This field is optional for On-off calculations and used only for documentation purposes. (6) Mol weight. Molecular weight (only with gas sizing). This field is optional for Onoff calculations and used only for documentation purposes. (7) Spec heats. Ratio of Specific Heats. (only with gas and steam sizing). This field is optional for On-off calculations and used only for documentation purposes.

(8) Consist %. The consistency of the pulp stock. (only with gas sizing). This field is optional for On-off calculations and used only for documentation purposes. (9) Special service req. By default service is Normal. If known that process in question has special requirement is known to cause friction increase due to the application or fluid other selection can be used accordingly. Other selection can affect to the recommended actuator sizing safety factor. (10) Design P. Max design pressure condition for the Tag. Input value for documentation. Value does not automatically affect to the valve selection within the program. Manual considerations in the valve selection must be made according to the requirements. (11) Design Tmax. Max design temperature for the Tag. Input value for documentation. Value does not automatically affect to the valve selection within the program. Manual considerations in the valve selection must be made according to the requirements (12) Design Tmin. Min design temperature for the Tag. Input value for documentation. Value does not automatically affect to the valve selection within the program. Manual considerations in the valve selection must be made according to the requirements (13) Inlet dia. Nominal diameter of the upstream pipeline. (14) Outlet dia. If not entered, the nominal diameter of the downstream pipeline is assumed to be the same as the inlet diameter. (15) Thickness. Pipe Wall Thickness. Enter either Thickness or Schedule. (16) Schedule. Piping schedule number. Enter either Thickness or Schedule. If neither is entered, then Sch 40 will appear as the default value. Needed only for noise calculation. (17) Inlet Temp. Temperature at upstream conditions. (18) DP-shutoff. Pressure differential across the valve at closed position. (19) Valve. By pressing this button you can open a valve type list and selection dialog. Valve type can be selected from here or by using fields 20, 21 and 22. (20) Type. Select valve type from the list. (21) Press rating. Pressure rating required. Select rating from the list. If you select All, valves available in all ratings are listed in Code column. (22)

Code. Select valve code from the list. (23) Size. Valve nominal size/reduction. Valve size to be selected manually. Sizes larger than pipeline cannot be used (24) Seat. Select valve seat type from the list. (25) Gland pack. Select gland packing type from the list. (26) Bearings. Select bearing type from the list. (27) Safety factor. Customer safety factor. The automatic actuator size selection is depending on the selected safety. The default value on the screen for customer value is 1.0. Minimum recommended safety factor by Metso is 1.2 for BTO and ETC positions which is taken into account automatically. (28) Actuator. By pressing this button you can open an actuator type selection dialog. Actuator type can be selected from here or by using field Code. (29) Code. Select actuator code from the list. (30) Size. Actuator size code. Will be automatically selected when Autom instead of manually selected size. (31) Supply press. Supply pressure of the instrumentation air to the actuator. (32) Spring rate. Spring rate or stiffness of the spring. Expressed as nominal pressure of the spring. Select a spring rate equal or lower than the available supply pressure.

Figure 21 . Input data for liquid and water sizing

Select the actuator spring when selecting the actuator size manually. The actuator spring rate is expressed as the nominal spring rate pressure: e.g. B1J, size 20, has three different spring rate options: 3 barG corresponding to BJK20, 4 barG corresponding to BJ20 and 5.5 barG corresponding to BJV20. In automatic sizing the program uses only the standard spring. 5.2 On-off calculation results

Figure 22. Max valve capacity for selected On-off valve.

Max capacity

Maximum flow capacity of the chosen control valve at fully open. FpCv is taking into account piping reducers and Cv is the inherent max Cv value.

Figure 23. Results for On-off calculation

Valve torques BTO (Break To Open) ETC (End To Close) The torque required to start opening the valve from closed position. Calculated with dp Shutoff. Equals to the To open torque with control valve calculation. The torque required to fully close the valve. Calculated with dp Shutoff. Equals to the To close torque with control valve calculation.

Actuator torques BTO (Break To Open) ETC (End To Close) Torque available of the selected actuator at the opening of the valve to the opening direction from fully closed position. Calculated with given Supply press. Torque available of the selected actuator at the closing of the valve to the closing direction. Calculated with given Supply press.

Safety factors BTO (Break To Open) ETC (End To Close) The calculated safety factor ie. the ratio of Actuator available BTO torque to the Valve required BTO torque for the selected valve and actuator. The calculated safety factor ie. the ratio of Actuator available ETC torque to the Valve required ETC torque for the selected valve and actuator.

5.2.1 Torque and safety factor details

More torque and safety factor details are available by enabling the Show details selection above the Calculate button.

Figure 24. Show details selection This selection will enable the so called running torque values.

Figure 25. Detailed torque and safety factor results with running torques Running torques definitions RTO is Run To Open, at the point of 50% travel towards the opening direction. RTC is Run To Close, at the point of 50% travel towards the closing direction. ETO is End To Open, at the point of 100% travel ie. to fully open position towards the opening direction. BTC is Break To Close, at the point of 100% travel when starting to close the valve towards the closing direction. At all above point the valve torques represents the valve required torque to operate the valve to the particular direction, actuator torque the available torque to operate the valve and safety factors the ratio of the available to the required torque.
5.2.2 Recommended safety factor

By default the minimum recommended safety factor for actuator selection for on-off valves is 1.2. In case the application or process is such that a bigger safety factor is to be used the program can take these needs into account in few ways and limitations. 1. Customer or process licensor requires a certain safety. User should input this value into Safety factor fields shown below. This will be handled in the program as the minimum value for automatic actuator selection.

Figure 26. Safety factor input 2. Application or valve service is known to have special requirements which are related to the particular fluid and might cause increasing valve friction. Depending of the valve type an increased safety might be recommended.

Figure 27. Special service requirement selection

3. High temperature with gases and low temperature with both liquids and gases might increase safety factor recommendation depending on the valve type. If there are several reasons - of those mentioned above - to increase safety factor the governing ie. the highest safety factor is applied. For selection of non-Metso actuators the recommended safety factor should always be applied and sent to actuator vendor. The recommended safety factor can be enabled to the user interface as in the selection on below.

Figure 28. Recommended safety factor selection The value will be seen as a result as below.

Figure 29. Recommended safety factor result 5.3 Printing On-off sizings Selections on the user interface and printing screen defines the amount of data to be printed on On-off valve sizing sheet. The standard print with BTO and ETC torques and safety factor appears with default selection.

Figure 30. Printing selections To print also the running torque details as mentioned in the previous chapter the Show details selection must be enabled at the On-off sizing interface. As can be seen in the above Figure Valve torques, Actuator torques and Safety factors can be selected separately ie. user can select the extent of the data in the printouts. As an example if a non-Metso actuator is to be used user can print only the Valve torque and for example the Recommended Safety Factor.

6 User settings
6.1 Units For most input data there are several possible unit selection options.

6.1.1 Changing a single unit

You can change any unit in the input or output grid. Simply click the unit field to access a list of possible units. Select the unit that you want. See the picture below. However, do take note that Inlet Press unit selection will dictate units for Press diff, Outlet press and Vap press (when applicable). For these three fields user cannot change unit for an individual field. The unist appearing are according to Inlet press unit selected, so that Vap press is given as absolute pressure (for example barA) and Press diff is given as plain unit (for example bar). Note also that for flow rate conversions, Nelprof does not provide mass flow/volumetric flow conversions or vice versa. This type conversions must be done manually. Flow Control Manual, has instructions how to to do the conversions.

Figure 31. Changing a unit for flow rate Nelprof will ask if you want to convert the old value to new unit. Select yes, cancel or no. If YES is selected the unit is changed and the value recalculated, if NO is selected the unit is changed but value is not recalculated and if CANCEL is selected the unit is not changed and the value is not changed.

7 User preferences
7.0.2 Setting project units

You can set units for one project by selecting that project from the Project Tree. Now you will see the Project Properties screen. In the lower left corner you will find the Set Project Units button and Set Project Parameters button. See the following picture.

Figure 32. Selection of units for sizing project Set the units as you want and press OK. Pressing the SI or US buttons will reset the SI or US units. The units will be valid in new sizings only. The units of existing sizings will not change. 7.1 Language selection for printing Note: The screen language is always English even though printing language is been changed. On-off and SIL Calculation print outs are only available in English.

8 File Functions
8.1 Saving data You can save all input data to the database by selecting File|Save All from the menu or by clicking the save all -button on the toolbar. You can save data of sizing/tag/project by selecting the sizing/tag/project from the tree and clicking the save button on the toolbar or by selecting File|Save. This will save data of that specified tree item and its sub-items.

9 Mass Operations
9.1 Selecting User can select sizings from tag tree by clicking tic boxes. If Tag is clicked, all sizings in that tag are selected. If all sizings of a tag are selected, tag is also selected. Same logic applies to project.

Figure 33. Selection logic

9.1.1 Mass Calculations

Mass calculation is started by selecting sizings that are wanted to be calculated. It does not matter, if check marks exist in other project levels than sizings as well. Mass Calculation starts from Calculation|Mass Calculation. Calculation takes 1-3 seconds each. Sizing names are highlighted after mass calculation depending if calculation was succesfull. Calculated sizings are marked with grey background.

Figure 34. Result report after Mass Calculation

9.1.2 Mass Editing

Any value of a sizing can be used for mass editing. Start mass editing by selecting sizings where the mass edit is wanted to apply. After that, change any sizing input field and select Edit|Mass Editing

Figure 35. Apply to all selected? -dialog

Figure 36. Mass Editing Ready

9.2 Adapters Like the Bernie adapter, there are already some other "std" adapters that can be used to export or import data in data format between different systems and Nelprof. The below std adapters are available by default and optionally you can create your own adapter for example by using the std adapters as an example for the mapping of parameters. An old mapping can be used as base for creating new.

Figure 37. Screen after selecting File|Export/Import|Advanced

Figure 38. Mapping of the parameters in the adapter 9.3 Importing data to quotation (for Metso users only) Control valve process and sizing data can be uploaded to a quotation in Metso sales system. Select your sizings with a selection in the box of the project tree. Then export selected tags using Bernie adapter by File|Export/Import|Export Bernie file. Save the exported file to your temp directory, where Bernie reads it automatically when import function is used in Bernie.

10 SIL calculation tool

10.1 Introduction Nelprof 6 SIL module is a tool to estimate the average probability of failure on demand (PFD ) for final element subsystem. PFD for final element subsystem is calculated according to IEC 61508. Final element subsystem considered in this SIL tool consist of valve, actuator and accessories including all necessary linkages. Accessories might include components such as partial stroke test device, solenoid valves or quick exhaust valves. SIL tool cover complete final element subsystem supplied by Metso, other subsystems (e.g. sensors or PLC) are not considered. Architecture of the final element subsystem including individual components (e.g. solenoids) is limited to single channel architectures 1oo1 and 1oo1D, where refers to diagnostics tests. SIL tool is intended for use in quotation and pre-selection phases. In case of final SIL calculation approved by Metso is needed, calculation must be accepted by Metso authorized persons. Failure rate values for valves, actuators and accessories in the tool are based on product certifications provided by 3rd parties such as TUV, Exida or Lloyds or generic databases such as Exida and OREDA. Contact Metso in case more detailed information is needed. 10.2 SIL calculation SIL tool consist of two pages : SIL edit page and Remarks page. SIL calculation is done at SIL edit page (see figure below) and remarks or notes can be added into calculation at the Remarks page.

Figure 39. New SIL calculation can be created by selecting Create | New SIL from the menu or clicking the New SIL button on the tool bar. SIL calculation can be created only under valve Tag. Enter or select all input parameters from top to bottom in all sections at SIL edit page and press Calculate button to perform SIL calculation for complete final element. Input parameters are located in final element setup, test intervals, valve, actuator and accessories section. Notice that SIL tool shows next and/or missing input parameter with yellow color. The results can be printed by selecting File | Print or clicking Print button in tool bar. SIL calculation sheet is printed by selecting Sizings in print menu.
10.2.1 Final element setup

Figure 40.

(1) Safety position. Safety position of the final element when demand from the safety system occurs. Select either open or close safety position. (2) Architecture. Architecture of the complete final element subsystem. Only 1oo1 or 1ooD voting are available. 1oo1 architecture consists of single channel without diagnostic tests between proof tests. 1oo1D architecture consists of single channel with diagnostics tests such as partial stroke tests. Select either 1oo1 or 1oo1D. (3) Diagnostic coverage. Diagnostic coverage of the final element provided by possible partial stroking testing. Diagnostic coverage is equal to 0 if 1oo1 architecture is selected. In case of 1oo1D architecture, the diagnostic coverage factors provided by Metso ValvGuard (VG) or typical manual partial stroke device can be selected. Safety position close and open has different diagnostic coverage.
10.2.2 Test intervals

Figure 41. (4) Full stroke test. Enter full stroke (proof test) interval of the final element in months. 12 months corresponds 365 days (8760 hours). The default value is 24 months. (5) Partial stroke test. Enter partial stroke interval of the final element in months or days. 12 months corresponds 365 days (8760 hours). The default value is 3 months. (6) Pneumatic test. Pneumatic test is ValvGuard internal diagnostic test which is not moving the valve assembly and affect only average probability of failure on demand for ValvGuard. Enter pneumatic test in days or select Disabled if pneumatic diagnostic test is not used. Note, in case of 1oo1 voting only full stroke test interval is required, partial stroke test and pneumatic test intervals are not shown in user interface.
10.2.3 Valve and actuator

Figure 42. (7) Valve. Select valve for the final element PFD calculation from available valve list e.g. D-SERIES (METAL SEAT). Dangerous failure rates (lambda D) in the database are conservative values. Soft seated valves values are for relatively clean service, and metal

seated valve values can be used also for severe service. Note, that valve selection and installation must be always be suitable for application and done according to manufacturers instruction in order verify reliable estimation of the probability of failure on demand. Contact Metso in case more information is needed regarding failure rate values. (8) Actuator. Select actuator for the final element PFD calculation from the available actuator list e.g. B-SERIES. Dangerous failure rates (lambda D) are conservative values for Metso pneumatic actuators. Note, that actuator selection and installation must be always be suitable for application and done according to manufacturers instruction in order verify reliable estimation of the probability of failure on demand. Contact Metso in case more information is needed regarding failure rate values. (9) MTTR. Mean time to repair. An average time required to repair failed valve or actuator. Enter MTTR in hours. The default value is 24 hours. (10) PFD. An average probability of failure on demand for valve (actuator) component in the final element subsystem. The value depends on lambda D, MTTR, diagnostic coverage, architecture and test intervals (see equation in chapter 10.2.6).
10.2.4 Accessories

Figure 43. (11) Intelligent PST. Select intelligent partial stroke device from the list : Metso ValvGuard VG800 (Hart), VG9000H (Hart) and VG9000F (Foundation Fieldbus). Dangerous failure rates (lambda D) are conservative values. Note, that device selection and installation must be always be suitable for application and done according to manufacturers instruction in order verify reliable estimation of the probability of failure on demand. Diagnostic coverage provided by pneumatic diagnostic test for ValvGuard is automatically taken into for PFD calculation for VG. Contact Metso in case more information is needed regarding failure rate values. Note, intelligent PST device menu is available only for 1oo1D architecture. (12) Instru. Select necessary instrumentation for the final element PFD calculation from the available instrumentation list. Dangerous failure rates (lambda D) are provided by instrument manufacturer or generic databases such as Exida or OREDA. Note, that device selection and installation must be always be suitable for application and done according to manufacturers instruction in order verify reliable estimation of the probability of failure on demand.Contact Metso in case more information is needed regarding failure rate values.

Abbreviations : SOV_xxx = Solenoid valve from different manufacturer SOV_xxx (DTT) = Solenoid valve, de-energized to trip. SOV_xxx (ETT) = Solenoid valve, energized to trip. SOV_xxx (DOUBLE) = Versa 316 solenoid, double solenoid version SOV_GENERIC 3-WAY = Generic 3/2 solenoid valve. AOV = Air operated valve, generic value. QEV = Quick exhaust valve, generic value. BOOSTER = Volumetric booster, generic value. QEV WITH DC = Generic quick exhaust valve with diagnostic coverage provided by partial stroke test BOOSTER WITH DC = Generic booster with diagnostic coverage provided by partial stroke test. RCI9H FOR VG9000H = Remote control interface unit for VG9000H. RCI9H should be selected for only VG9000H in case connected to SIS system with digital output (DO). In case VG9000H is connected to SIS with analog output RCI9H is not needed (see examples below) (13) MTTR. Mean time to repair. An average time required to repair failed component. Enter MTTR in hours. The default value for PST device and instrumentation is 4 hours. (14) PFD. An average probability of failure on demand for VG and selected instrumentation components. The value depends on lambda D, MTTR, diagnostic coverage, architecture and test intervals (see equation in next chapter). Note, no diagnostic coverage for instrumentation components except QEV WITH DC and BOOSTER WITH DC.
10.2.5 Total PFD and SIL suitability

Figure 44. (15) PFD. An average probability of failure on demand for complete final element subsystem. Total PFD = PFDv + PFDa+PFDpst+PFDi. The value depends on lambda D, MTTR, diagnostic coverage, architecture and test intervals (see equation in next chapter). Press calculate button to perform PFD calculation for components and total final element. PFDv = PFD for valve PFDa = PFD for actuator PFDpst = PFD for intelligent PST device PFDi = sum of PFDs of selected instruments

(16) SIL. The Safety integrity level (SIL). Complete final element is suitable to be in use up to and including given SIL level. SIL is defined according to following table : SIL 1 0.1 > PFD total 0.01

SIL 2 0.01 > PFD total 0.001 SIL 3 0.001 > PFD total 0.0001 SIL 4 0.0001 > PFD total 0.00001
10.2.6 PFD equations

An average value of probability of failure on demand for 1oo1D architecture with diagnostic is given by equation

where DC is diagnostic coverage, D is dangerous failure rate, TI_FST is full stroke test interval, TI_PST is partial stroke test interval and MTTR is mean time to repair. Diagnostic coverage provided by partial stroke is utilized for valve, actuator, quick exhaust valve and volume booster. Diagnostic test for solenoid or air operated valve is not available. ValvGuard is using diagnostic coverage provided by pneumatic diagnostic test. PFD equation for 1oo1 voting without diagnostic test is similar to 1oo1D except diagnostic coverage is equal to 0.
10.2.7 Examples

Example 1 Architecture : 1oo1 D

Valve : Metal seated D-series ball. Actuator : B-series. Intelligent PST device : VG9000H to perform partial stroke test and safety function. Safety system with digital output. Full stroke test interval : 5 years. Partial stroke test interval : 3 months.

Figure 45.

Example 2 Architecture : 1oo1 D Valve : Metal seated D-series ball. Actuator : B-series. Intelligent PST device : VG9000H to perform partial stroke test and safety function. Safety system with analog output (no RCI9H is needed). Full stroke test interval : 5 years. Partial stroke test interval : 3 months.

Figure 46. Example 3 Architecture : 1oo1 D

Valve : Metal seated D-series ball. Actuator : B-series. Intelligent PST device : VG9000H to provide partial stroke test. Solenoid : Asco 327 series, de-energized to trip. Solenoid valve to perform safety function. Safety system with digital output. Full stroke test interval : 5 years Partial stroke test interval : 3 months

Figure 47.

Example 4 Architecture : 1oo1 Valve : Soft seated seated 9000 series ball Actuator : VPVL rack and pinnion actuator Solenoid : Asco 327 series, de-energized to trip. Solenoid valve to perform safety function. Safety system with digital output Full stroke test interval : 1 year

Figure 48.

11 Help
11.1 Users Guide

The Users Guide is installed in electronic form in Nelprof. You can view help topics by selecting Help|Help Topics from the main menu. Information regarding Nelprof 6.0 use is easily found by double clicking to the desired chapter marked with book-icon (or by clicking and pressing enter) and then clicking on the suitable title. All topics can be printed out on the printer from File|Print. 11.2 Flow Control Manual The Flow Control Manual is installed in electronic form in Nelprof. You can read the manual by selecting Help|Flow Control Manual from the main menu. The Flow Control Manual offers a quick way of finding more detailed information about control valves and flow and control theory. Within the Flow Control Manual you can click the green text (or select and press ENTER) to display a new topic. You can also use the and buttons to move from one topic to another. All topics can be printed out on the printer from File| Print. 11.3 Control Valve Sizing Coefficients The Control Valve Sizing Coefficients include key control valve data in electronic form. Data is presented in tabular and graphical format so as to cover each valve with its individual Nelprof code. You can read the manual by selecting Help|Sizing coefficients from the main menu.All topics can be printed out on the printer from File|Print. 11.4 Metso Automation online By selecting Help|Metso Automation online from the main menu, you can access Metso Automation website (www.metsoautomation.com). To do this you need to have working internet connection set-up to your PC. 11.5 About By selecting Help|About from the main menu, you can view basic information of your Nelprof program. 11.6 Version By selecting Help|Version from the main menu, you can view version information for the databases you are currently using.

12 Appendix 1. Valves included in Nelprof

See contents for Control Valve Sizing Coefficients.

13 Appendix 2. Nelprof load factor for rotary control valves

The recommended maximum load factor values are as follows: Opening Closing Control Open Control Close Less than 90% Less than 90% Less than 60% Less than 60%

A particular application may dictate lower values.

14 Appendix 3. General control valve selection guidelines

Control valve size and flow characteristic Nominal Valve Size

Not greater than the nominal pipe size. Not smaller than 1/2 the nominal pipe size.

Installed Gain

The installed relative gain in the process operating range should be greater than 0.5, and The maximum gain should not be greater than the minimum gain times two.

Clean Gas Applications Max Exit Velocity

0.5 Mach for continuous control 0.7 Mach for infrequent duty (for example, flaring and venting applications).

Max Calculated SPL

110 dB(A) to avoid strong mechanical vibrations. 85 dB(A) often required by laws and regulations.

Insulated Pipeline Predicted noise is dampened by 1 to 2 dB(A)/10mm, 3-5 dB(A)/inch. Note: Vibration level does not dampen with insulation. Clean Liquid Applications Max Inlet Velocity Continuous Duty

Butterfly valves 7 m/s, 23 ft/s. Cage-guided globe valves 15 m/s, 50 ft/s. All other valves 10 m/s, 32 ft/s.

Infrequent Duty

Butterfly valves 8.5 m/s, 27 ft/s. Cage-guided globe valves 18 m/s, 60 ft/s. All other valves 12 m/s, 39 ft/s.

Max Calculated SPL

With uninsulated sch. 40 pipe. 80 dBA up to 80 mm / 3" valve size. 85 dBA 100 mm / 4" to 150 mm /6" valve size. 90 dBA 200 mm / 8" to 350 mm /14" valve size. 95 dBA 400 mm / 16" and larger

Note: 85 dB(A) often required by laws and regulations.

Max Delta P Terminal pressure drop, unless in flashing-flow application. However, mechanical pressure and temperature limits of valve must not be exceeded. Pulp Stock Applications

Maximum o R-series segment ball valves 7 % Consistency o R-series valve with Q-trim 3.5% o Medium consistency Version R2S 19% o Butterfly valves, below 250 mm / 10" 4% o Butterfly valves, above 250 mm / 10" 7%

Black liquor applications

Solid content < 65% o High-performance butterfly valves Solid content > 65% o Ball valves

15 Cavitation noise level is high.

THEORY Cavitation is a phenomenon appearing in liquids flow under certain flow conditions. Cavitation develops in two stages. First, as the pressure of the liquid is reduced below the liquid vapour pressure when throttling, vapour bubbles form in the liquid. Then, recovery of pressure after vena contracta raises the pressure above the liquid vapour pressure causing collapse of the vapour bubbles. The collapsing bubbles cause strong micro jets, which in high intensity cavitation may cause damage to materials. Cavitation also is the main reason for liquid flow noise. High noise level in liquid flow is an indication of high cavitation intensity. PROBLEM When the valve downstream pressure is relatively close to liquid vapour pressure and valve upstream pressure is high compared to downstream pressure the valve starts to cavitate. The intensity of cavitation is not harmful for the valve closeto the onset point, but when pressure drop is further increased the intensity increases and may start to wear the valve or downstream piping. High pressure drop over the valve, compared to upstream pressure, may result to cavitation causing material damages and noise. The predicted noise level depends on flow situation and also on the valve and valve size in question. SOLUTION

The main principle of reducing cavitation noise is to select a so called low recovery anticavitation valve. A typical anticavitation valve is a multistage valve. Noise of a cavitating valve should not be dampened with piping insulation, because that way the real reason for noise is not effected and wears of materials is not reduced. It is also possible to reduce the wear of a cavitating valve by selecting wear resistant materials. Stainless steel, stellite and ceramics are good examples of cavitation resistant materials. Carbon steel is not recommended to be used in cavitating service. REFER TO FLOW CONTROL MANUAL:

3. Liquid flow 3.3 Cavitation and flashing - 3.3.1 Cavitation phenomenon 3.4 Cavitation and hydrodynamic noice abatement

16 Control torque of the actuator is too small.

THEORY To enable smooth control of the control valve the load factor must be small enough. Specially for high friction constructions the load factor has significant meaning. Load factor means required valve torque divided by available actuator torque. PROBLEM High load factor means that valve accuracy is limited, tuning of the positioner and the whole control loop is difficult and the response time for signal changes is long. SOLUTION Select larger actuator or check if supply air pressure can be increased enough to enable use of selected actuator. Also the seat, bearing and gland constructions can be changed to reduce the required torque.

17 Flow marginal is large.

THEORY Valve fully open flow rate calculation takes to account the change in pressure drop as a function of flow rate. In a typical piping system where piping losses take a great portion of the total pressure losses the maximum flow rate is limited by the piping losses. PROBLEM Typically very large flow marginal is result of oversized control valve or unsuitable flow characteristics. When required flow rate is considerably less than calculated valve fully open flow the control accuracy is decreased and control range is narrow. SOLUTION

If the required flow rate is considerably less than calculated valve fully open flow then selecting a smaller size valve, lower capacity valve type or reduced capacity trim will help. Sometimes this situation is result of using an equal percentage inherent characteristics in system where the pressure does not change as function of flow rate, in those cases a linear or close to linear inherent characteristic will help. REFER TO FLOW CONTROL MANUAL:

1.4 Pressure loss behaviour of piping components 2. Control valve installed performance - 2.1 General 2.4 Control valve flow characteristics

18 Flow marginal is small.

THEORY Valve fully open flow rate calculation takes to account the change in pressure drop as a function of flow rate. In a typical piping system where piping losses take a great portion of the total pressure losses the maximum flow rate is limited by the piping losses. PROBLEM When required maximum flow rate is very close to calculated valve fully open flow the reserve of capacity is very small. SOLUTION Selecting a larger size or higher capacity control valve may help if the problem is small capacity reserve. In some piping systems the piping pressure losses may restrict the flow so that changing valve size does not help. In those cases there is a possibility to decrease piping losses by increasing the pipe diameter, but usually the only thing to do is to use high capacity valves and split range if the control range is wide. REFER TO FLOW CONTROL MANUAL:

1.4 Pressure loss behaviour of pipe components 2. Control valve installed performance - 2.1 General 2.4. Control valve flow characteristics

19 Flow velocity in valve inlet port is high.

THEORY High flow velocities in the valve may cause wear of valve internals and body. Erosion is strongly dependent on flow velocity and also wear caused by cavitation and corrosion increases as velocity increases. PROBLEM If the flow velocity is high the seating area of valve trim may wear leading to decreased tightness. Also other parts of the valve may be exposed to wear especially in erosive, corrosive and cavitating conditions. In some valve types high velocities may also cause dynamic forces to valve trim leading to unstable operation of the valve. SOLUTION Increasing the valve nominal size will decrease the inlet velocity. Sometimes it is necessary to use also reduced capacity trims in order to keep the valve opening within acceptable level. REFER TO FLOW CONTROL MANUAL:

1. Introduction to pipeline flow - 1.1 General 1.5 Valve dynamic torque 3. Liquid flow 3.3.1 Cavitation phenomenon 3.4 Cavitation and hydrodynamic noise abatement 3.7 Recommended flow velocities for liquids

20 Flow velocity in valve outlet port is high.

THEORY High flow velocities in the valve may cause wear of valve internals and body. Erosion is strongly dependent on flow velocity. PROBLEM

If the flow velocity is high the seating area of valve trim may wear leading to decreased tightness. Also other parts of the valve may be exposed to wear especially in erosive conditions. In some valve types high velocities may also cause dynamic forces to valve trim leading to unstable operation of the valve. SOLUTION Increasing the valve nominal size will decrease the outlet velocity. Sometimes it is necessary to use also reduced capacity trims in order to keep the valve opening within acceptable level. Because of gas compressibility also increasing valve downstream pressure will decrease the valve outlet velocity. Valve downstream pressure can be increased with a fixed restriction, like diffuser, installed downstream of the valve. REFER TO FLOW CONTROL MANUAL:

1. Introduction to pipeline flow - 1.1 General 1.5 Valve dynamic torque 4. Gas and steam flow 4.5.1 Source treatment 4.6 Recommended flow velocities and limits for noise levels

21 Installed flow characteristics have not been analysed.

THEORY The installed flow characteristic can be predicted if the following conditions are true: Condition 1: The process is such that a specific flow corresponds to a specific pressure drop across the valve. Condition 2: Pressure drop changes across the control valve are dependent on pressure losses in the piping system such that the sum of those pressure losses is proportional to the square of flow velocity. Installed flow characteristics have not been analysed if viscosity is given for liquid. PROBLEM

Given flow versus pressure drop and upstream pressure dependence does not fit in the assumptions needed in installed flow characteristic calculation. Flow cases may be from different process situation like start up and running conditions. In some processes the pressure may vary independently from flow rate and in such processes the flow characteristic calculation is not performed. Calculation can be performed in several portions each including one process situation. SOLUTION The different flow situations must be separated from each other in order to calculate the characteristics. For example start up conditions present one flow condition for which flow characteristic can be calculated and the actual running conditions would be another separate flow characteristic calculation. REFER TO FLOW CONTROL MANUAL:

2. Control valve installed performance - 2.1 General 2.4 Control valve flow characteristics 2.4.1 Inherent flow characteristic 2.4.2 Installed flow characteristic 2.4.3 Installed gain 2.4.4 Calculation methods - 2.4.4.1 Procedure

22 Maximum gain within the control range is high.

THEORY The quality of the valve installed flow characteristic curve with respect to valve controllability and accuracy can be measured by means of a valve installed gain curve. The gain of an installed valve is the change in relative flow rate divided by the change in relative travel. In other words the change in relative flow rate is the gain multiplied by the change in the valve relative travel. PROBLEM If the gain value is too low or too high, or if it changes considerably in the process operating range, process control will generally become very difficult. Too high maximum gain value means in practice that the control accuracy is poor. Change in valve position corresponds to very large change in flow rate. SOLUTION

Too high maximum gain value is usually result of over sizing of the valve in which case selecting a smaller size valve will improve the situation. If maximum gain is too high with high openings then the situation may be improved by using a valve with more linear inherent flow characteristic or by using a fixed resistor downstream or upstream of the valve. If maximum gain is too high with low openings then the situation may be improved by using a valve with more equal percentage flow characteristic or in many cases selecting a smaller size valve will help. It is also possible that the system pressure losses compared to valve pressure drop with maximum required flow rate are very high. In that case the solution may be split range or signal modification. REFER TO FLOW CONTROL MANUAL:

2. Control valve installed performance - 2.1 General 2.4 Control valve flow characteristics 2.4.3 Installed gain 2.4.6 Control valve characterization

23 Minimum gain within the control range is small.

THEORY The quality of the valve installed flow characteristic curve with respect to valve controllability and accuracy can be measured by means of a valve installed gain curve. The gain of an installed valve is the change in relative flow rate divided by the change in relative travel. In other words the change in relative flow rate is the gain multiplied by the change in the valve relative travel. PROBLEM If the gain value is too low or too high, or if it changes considerably in the process operating range, process control will generally become very difficult. Low gain values mean in practice that valve response to signal change is slow. Change in valve position corresponds to very small change in flow rate. Low gain minimum value with one valve opening usually means also high gain value with another opening. SOLUTION

Low gain values are usually result of unsuitable inherent flow characteristic of the valve for the flow conditions in question. If minimum gain is too low with small openings then the situation may be improved by using a valve with more linear inherent flow characteristic. If minimum gain is too low with high openings then the situation may be improved by using a valve with more equal percentage flow characteristic. In many cases over sizing of the valve also causes low gain values with high openings and in that case selecting a smaller size valve will improve the situation. It is also possible that the system pressure losses compared to valve pressure drop with maximum required flow rate are very high. In that case the solution may be split range or signal modification. REFER TO FLOW CONTROL MANUAL:

2. Control valve installed performance - 2.1 General 2.4 Control valve flow characteristics 2.4.3 Installed gain 2.4.6 Control valve characterization

24 Noise level is high.

THEORY Aerodynamic noise is mainly caused by interaction of shock waves and turbulence with high pressure ratios and by large flow rates with low pressure ratios. With low pressure ratios the high noise levels are usually related very high capacities and at the same time large nominal valve sizes. With increasing pressure ratio the noise level becomes more and more of a problem also for small size valves. Shock waves and shock wave patterns are developed downstream of the valve throttling point causing the increasing noise level. PROBLEM To prevent mechanical damages of a valve and to ensure operation of control valve instrumentation, it is recommended that valves having predicted sound pressure levels exceeding 110 dBA should be avoided. When sound pressure level exceeds 100 dBA there is a possibility that the vibration related to high noise levels may disturb the operation of the process instrumentation.

In practice the limit set by laws and regulations is around 85 dBA, which is the risk limit for long term noise level for humans. SOLUTION Aerodynamic noise abatement can be basically divided into two categories source and path treatment. Source treatment is in practice using low noise valves like multistage valves or using fixed restriction, like diffuser, downstream of the valve. Path treatment means dampening the noise that already is generated in throttling process. Typically path treatment is using an inline silencer or insulation in the piping. Pipe insulation may be used to dampen the noise in gas and steam lines, particularly in steam lines, where there is already thermal lagging. The preferred ways of noise abatement are always the source treatment methods. This is because when source treatment is used the high mechanical vibration levels always associated with noise can be prevented, thus ensuring reliable operation of the process. A combination of source and path treatment often provides the most economical sound dampening system. REFER TO FLOW CONTROL MANUAL:

4. Gas and steam flow 4.3 Aerodynamic noise - 4.3.1 Aerodynamic noise generation 4.4 Atmospheric venting 4.5 Aerodynamic noise abatement

25 Opening or closing torque of the actuator is too small.

Opening or closing torque of the actuator is too small. PROBLEM Opening the valve requires enough torque to overcome the frictional forces caused by the maximum shutoff pressure difference across the valve. For some valve types also seat load must be exceeded. Closing the valve for some valve types requires extra torque to achieve the required tightness. SOLUTION

Select larger actuator or check if supply air pressure can be increased enough to enable use of selected actuator. Also the seat, bearing and gland constructions can be changed to reduce the required torque.

26 Opening or closing torque with maxi dp is too high.

PROBLEM The valve shaft is not strong enough to stand the frictional forces caused by the pressure difference. Strength of the shaft depends on the material and on temperature. On high temperatures the strength may be considerably smaller than in room temperature. Temperature affect has not been taken to account in here. This note is for basic material used in each valve type. SOLUTION Select stronger stem material. Also the seat, bearing and gland constructions can be changed to reduce the required torque. Valve opening with maximum required capacity is high.

27 Output thrust of the actuator is too small.

PROBLEM The actuator selected is not able to operate the valve over the whole operating range. The actuator may not be able to open or close the valve properly under given process data. It is also possible, that control performance of the valve is impaired or the valve is incapable to reach its operating point. SOLUTION Check the process data or choose a bigger actuator. The automatic actuator selection will guide you.

28 Pressure is too high for the valve size.

PROBLEM Inlet pressure or shut-off pressure difference is too high for the valve size with the selected seat material. Actuator sizing cannot be done. SOLUTION Select a smaller valve, change the seat material or check the process pressures.

29 Ratio of maximum and minimum gain within the control range is high.
THEORY The quality of the valve installed flow characteristic curve with respect to valve controllability and accuracy can be measured by means of a valve installed gain curve. The gain of an installed valve is the change in relative flow rate divided by the change in relative travel. In other words the change in relative flow rate is the gain multiplied by the change in the valve relative travel. PROBLEM If the gain value is too low or too high, or if it changes considerably in the process operating range, process control will generally become very difficult. High change of the gain within control range means in practice that the stability and accuracy of the control valve will change as the installed gain changes throughout the control range. This may cause some problems when tuning the controller. SOLUTION Large changes in gain value are usually a result of over sizing of the valve in which case selecting a smaller size valve will improve the situation. If gain is high with low openings and low with high openings then the situation may be improved by using a valve with more equal percentage flow characteristic or in most cases selecting a smaller size valve will help. If gain is high with high openings and low with low openings then the situation may be improved by using a valve with more linear inherent flow characteristic or by using a fixed resistor downstream or upstream of the valve. It is also possible that the system pressure losses compared to valve pressure drop with maximum required flow rate are very high. In that case the solution may be split range or signal modification. REFER TO FLOW CONTROL MANUAL:

2. Control valve installed performance - 2.1 General 2.4 Control valve flow characteristics 2.4.3 Installed gain 2.4.6 Control valve characterization

30 Supply pressure of the instrumentation air to the actuator is insufficient.

PROBLEM The supply air pressure affects selection of the spring for single-acting actuators. The supply pressure should be equal or higher than the nominal pressure of the spring (spring rate). SOLUTION Check the supply air pressure.

31 Torque in control position with control dp is too high.

PROBLEM The valve shaft is not strong enough to stand the frictional forces caused by the pressure difference. Strength of the shaft depends on the material and on temperature. On high temperatures the strength may be considerably smaller than in room temperature. Temperature affect has not been taken to account in here. This note is for basic material used in each valve type. SOLUTION Select stronger stem material. Also the seat, bearing and gland constructions can be changed to reduce the required torque.

32 Valve is in flashing flow conditions.

THEORY When the downstream pressure of a control valve is less than the liquid vapour pressure, part of the liquid is vapourised and remains as vapour downstream of the valve. Flow downstream of the valve is part liquid and part vapour. In some cases where upstream pressure is very close to vapour pressure, flow may occur in two phases upstream of the valve. PROBLEM Flashing flow may cause mechanical difficulties, like erosion and vibration, but unlike cavitation, the reason is the high velocity of the two phase flow stream. High velocity is due to the larger vapour volume compared with liquid.

Flashing flow can not be avoided by selection of valve type because flashing is result of flow conditions. By selection of the control valve the fact that downstream pressure is below vapour pressure. SOLUTION Materials should be selected according to resistance for erosive wear. Valve type should be selected so that minimum amount of wear would be caused by direct flow impact on valve body and internals downstream of the throttling point. REFER TO FLOW CONTROL MANUAL:

3. Liquid flow 3.3 Cavitation and flashing - 3.3.1 Cavitation phenomenon 3.4 Cavitation and hydrodynamic noise abatement

33 Valve nominal size is larger than pipeline nominal size.

THEORY Valves larger than pipeline nominal size are not recommended. PROBLEM Installing a valve larger than pipeline nominal size is difficult and does not usually give any extra benefit compared to a line size valve. SOLUTION Select a valve having equal or smaller diameter than pipeline. REFER TO FLOW CONTROL MANUAL:

2. Control valve installed performance - 2.1 General

34 Valve nominal size is small compared to pipeline nominal size.

THEORY

Small movement of piping creates forces in to the flange connections. Movement may be result of temperature changes, vibrations or actual movement of piping brackets. PROBLEM Large size pipe connected to a small size valve creates forces into flange connections. These forces may cause bending and stresses. Flange connections may start to leak if the forces are large enough, or in the worse case they may result to breaking of components. A small movement for a large diameter pipe may cause big movement for a small nominal size valve resulting big stresses. SOLUTION Usually the solution is to select a larger nominal size valve and in many cases also a low capacity trim is required to keep the control range acceptable. A rule of thumb is that valve nominal diameter should be at least half of the pipeline diameter. REFER TO FLOW CONTROL MANUAL:

2. Control valve installed performance - 2.1 General

35 Valve opening with maximum required capacity is high.

THEORY Valve sizing to very high relative openings contains a risk of too small capacity. This may be a result of change in flow conditions or uncertainties in original flow conditions. Also blocking of piping may result to requirement of larger capacities than calculated. PROBLEM High valve relative opening means that the reserve of capacity is small and there is a risk that the valve capacity will not be sufficient because of uncertainties in the flow conditions. In many cases the flow conditions also change during the operation of the plant. SOLUTION If the valve opening is too high then selecting a larger nominal size valve or high capacity valve will help. If even capacity of a pipeline size full bore ball valve is not enough, then probably the flow data or flow units have a misspelling or an error.

REFER TO FLOW CONTROL MANUAL:

2. Control valve installed performance - 2.1 General 2.4.1 Inherent flow characteristic 2.4.2 Installed flow characteristic 2.4.3 Installed gain 2.4.5 Control valve accuracy

36 Valve opening with maximum required capacity is low.

THEORY Control valve rangeability is the range of flow rates that can be controlled. For an installed control valve the control range depends on the control valve installed flow characteristic. For an oversized valve the control range is narrow. PROBLEM Low valve relative opening with maximum required capacity means that the valve is oversized and may result to decreased control accuracy and narrow control range. A large valve is also more expensive than a small one. SOLUTION If the valve opening with maximum relative flow rate is too low then selecting a smaller size valve, lower capacity valve type or reduced capacity trim will help. REFER TO FLOW CONTROL MANUAL:

2. Control valve installed performance - 2.1 General 2.4.1 Inherent flow characteristic 2.4.2 Installed flow characteristic 2.4.3 Installed gain 2.4.5 Control valve accuracy

37 Valve opening with minimum required capacity is low.

THEORY

With very small valve openings a small change in valve travel results to a large relative change in flow rate. In other words this means lower relative accuracy with small opening angles. For some valve types high dynamic forces may cause unstable operation of the valve with very small openings. PROBLEM Low valve relative travel with minimum required capacity may result to decreased control accuracy. For some valve types flow causes very high dynamic forces with small openings. This problem is mainly related to valves in which the sealing is performed with linear motion of the trim. SOLUTION If the valve opening is too low then selecting a smaller size valve, lower capacity valve type or reduced capacity trim may help. If the required control range is extremely wide then an equal percentage inherent characteristic trim may help. A rotary valve, like a ball valve, has typically higher rangeability than a linear motion valve. In the most difficult cases split range has to be used. REFER TO FLOW CONTROL MANUAL:

2. Control valve installed performance - 2.1 General 2.4.1 Inherent flow characteristic 2.4.2 Installed flow characteristic 2.4.3 Installed gain 2.4.5 Control valve accuracy

38 Valve shaft diameter is smaller than actuator hole.

PROBLEM The diameter of the valve stem is smaller than the hole in the actuator. Selected actuator can be mounted on top of the selected valve only by special fitting. The valve stem may not stand the actuator torque especially at high temperatures unless it is made out of very strong material. SOLUTION

Contact factory for special fittings and check the stem strength with the factory. Check if supply air pressure can be increased enough to enable use of smaller actuator.

39 Valve shaft diameter is too big to fit into the actuator hole.
PROBLEM The diameter of the valve stem is larger than the hole in the actuator. Selected actuator can be mounted on top of the selected valve only by special fitting. Typically this also means that actuator torque is not adequate for the valve. SOLUTION Select a bigger actuator or contact factory for special fittings. In case of special fittings check the actuator selection with the factory.

40 Valve does not have enough capacity.

THEORY Required valve capacity is calculated to each flow cases according to given flow and pressure conditions. Calculation is based on ISA/IEC standards. PROBLEM Valve capacity may be too small in case of too large flow rate or too low pressure drop. SOLUTION Problem can be solved by selecting a larger nominal size valve or high capacity type valve. If even a full bore pipeline size ball valve does not give enough capacity then there is probably a mistake or misspelling in given flow conditions or in the units. REFER TO FLOW CONTROL MANUAL:

3. Liquid flow 3.2 Sizing equations for liquid flow 4. Gas and steam flow 4.2 Sizing equations for gas and steam flow

41 Pressure is too high for the valve type.

PROBLEM Inlet pressure or shut-off pressure difference exceeds the pressure rating of the valve. Actuator sizing cannot be done. SOLUTION Select another valve type or check the process pressures.

42 Cavitation intensity is high.

THEORY Cavitation is a phenomenon appearing in liquids flow under certain flow conditions. Cavitation develops in two stages. First, as the pressure of the liquid is reduced below the liquid vapour pressure when throttling, vapour bubbles form in the liquid. Then, recovery of pressure after vena contracta raises the pressure above the liquid vapour pressure causing collapse of the vapour bubbles. The collapsing bubbles cause strong micro jets, which in high intensity cavitation may cause damage to materials. Cavitation also is the main reason for liquid flow noise. High noise level in liquid flow is an indication of high cavitation intensity. PROBLEM When the valve downstream pressure is relatively close to liquid vapour pressure and valve upstream pressure is high compared to downstream pressure the valve starts to cavitate. The intensity of cavitation is not harmful for the valve close to the onset point, but when pressure drop is further increased the intensity increases and may start to wear the valve or downstream piping. High pressure drop over the valve, compared to upstream pressure, may result to cavitation causing material damages and noise. The predicted noise level depends on flow situation and also on the valve and valve size in question. SOLUTION The main principle of reducing cavitation noise is to select a low recovery anticavitation valve. A typical anticavitation valve is a multistage valve. A fixed resistor downstream of the valve will increase the valve downstream pressure and thus decrease the cavitation intensity of the valve. The problems with the fixed resistors come from the fact that it will work only with very narrow flow range. It is also possible to reduce the wear of a cavitating valve by selecting wear resistant materials. Stainless steel, stellite and ceramics are good examples of cavitation resistant materials. Carbon steel is not recommended to be used in cavitating service.

REFER TO FLOW CONTROL MANUAL:

3. Liquid flow 3.3 Cavitation and flashing - 3.3.1 Cavitation phenomenon 3.4 Cavitation and hydrodynamic noise abatement