Basic Control Valve

Sizing and Selection

 DeZurik Operation

V a lv e
S iz in g
What is Valve Sizing?

It is a procedure by which the dynamics of a process system

are matched to the performance characteristics of a valve.

This is to provide a control valve that will best meet the needs
of managing flow within that process system.

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Flow Coefficient (CV)
 Thevalveflowcoefficient, CV isthenumber of U.S.
gallonsper minuteof water at 60degreesF which will
passthrough agiven flowrestriction with apressuredrop
of 1 psi.
 For example, acontrol valvewhich hasaflowcoefficient,
or CV, of 12hasan effectiveport areathat it passes12
gallonsper minuteof water with 1 psi pressuredrop.
 DeZurik Operation

V a lv e
SBasicizinformation
in g requirements for effective valve sizing
For the system:
Pressure before and after the control valve, ΔP
Flow rate, quantity and units, Q
Process temperature with units, T
Properties of the media, (viscous, fiber suspension, gaseous
its vapor pressure, sometimes molecular weight)
For the control valve:
Flow capacity (Cv), inherent throttling curve,
Kc (Cavitation Index), FL² (Critical Flow factor)

October 2005
Delta P (∆P)
 ∆P Sizingisthepressuredropacrossthevalveused for
control valvesizingat aspecificflowrate.
 Most applicationshavemultipleflowsfor sizingwith
different ΔPfor each
 In agiven system, higher flowratesgenerally result in
lower pressuredropacrossthevalve.
 F lo w
C h a r a c t e r is t ic s
 Control valveflowcharacteristicsaredetermined principally by thedesign
of thevalvetrim.
 Thethreebasicflowcharacteristicsavailableare:
 Quick Opening
 Linear
 Equal Percentage (=% )
 A modified characteristic(sometimescalled modified percentage) generally
fallingbetween thelinear and equal percentagecharacteristicsmay also be
available.
Why Use Equal Percentage
 Providesequal percentage
increasesin rateof flowfor
equal incrementsof plug
movement.

 Providesthebest choiceof flow

characteristicfor most systems.
 DeZurik Operation

V a lv e S iz in g -
C a isvcavitation
What it a t andio what
n does it do to valves?
Cavitation is a 2-stage activity where a portion of the liquid
media drops below vapor pressure. This part will boil (vaporize).
In stage two, slightly downstream, pressure recovery takes place
and the vapor bubbles collapse.

The condition known as “critical flow” is an extension of cavitation

in that it simply gets worse as the pressure drop increases. This is
to the point that changes (reductions) in downstream pressure
no longer influence flow rate.

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Fluid Recovery Factor (FL)
When afluid passesthrough thevalveorifice,
thevelocity increases. Thisvelocity increaseis
accompanied by aproportional decreasein
pressure. Velocity reachesamaximumand
pressureaminimumat thesmallest cross
sectional flowareadownstreamof theorifice
(thevenacontracta).

Downstream of the vena contracta the fluid decelerates and

consequently the pressure increases or recovers (giving us the term
pressure recovery). Different valve types exhibit different recovery
factors which becomes an important consideration in valve selection.
Fluid Recovery Factor (FL)
Thefluidrecovery factor (FL) FL~(P1-P2)/(P1- PVC)
iseffectively an index of
pressurerecovery in acontrol
valve. High FL valuesindicate
lowpressurerecovery wherea
lowFL valueisan indication of
high pressurerecovery.
Higher FL valuesresult in
better resistancetocavitation.
 V a lv e s iz in g - C a v it a t io n
Collapseof thebubblescreated by cavitation producenoise, likegravel in the
line.
Bubblesthat collapsein contact with thevalveor pipecreatedamage.

Cavitation can becontrolled with special valvetrimsin sometypesof valves.

Cavitation should beavoided in all circumstances.

 DeZurik Operation

V a lv e
S
Whatiz in g
is “Flashing”?

It is a condition where the downstream pressure is below the

vapor pressure of the incoming fluid and allows some of the
liquid to become vapor.

Flashing does not create noise or damage in the valve as with

cavitation. It can, however, create damage to the downstream
piping due to high velocity.

A control valve will function quit well under these circumstances. Yes!

October 2005
 DeZurik Operation

V a lv e
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Characteristics

Systems driven by centrifugal pumps lose pressure two ways

As the flow increases the pump pressure declines
As the flow increases pipeline friction losses increase
Using a valve with equal percentage or parabolic characteristics
will produce an installed characteristic that is more linear.

October 2005
Inherent vs. Installed Characteristics
 Inherent flowcharacteristicisdefined astherelationship between
flowand valvestrokeat constant pressuredrop. It isuniquetovalve
construction and dependsprimarily on geometry of thethrottling
trimandbody flowpassagesand isdeterminedby flowtesting.
 Theinherent flowcharacteristicchangeswhen installedin apiping
system. Theresult istheinstalled flowcharacteristic. Assystem
pressuredrop absorbedby thecontrol valveisreduced, thegreater
thedeviation fromtheinherent state.
 Ideally acontrol valveshouldbesizedtoabsorb15%-25% of system
pressure.
 DeZurik Operation

V a lv e
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What is desired ?
100
- After installation, Equal Percent
80
generally it should
be near linear. 60 Modified Parabolic

% Cv
40
Why? Linear

20
- To provide a more Quick Opening

predictable flow 0
0 20 40 60 80 100
change in response
% Open
to each incremental valve
position change

October 2005
Control Valve Seat Leakage
 It isbecomingmorecommon to expect acontrol valveto provideisolation
duty, thusallowableleakagebecomesmoreimportant.
 Control valveseat leakageisdesignated by theclassification of
ISA/ANSI-70-2
 LeakageclassesareclassI-VI.
 ClassesI-V aremeasured usingwater, classVI ismeasured usingair.
 Themost common classfor metal seated control valvesisclassIV. (0.01%
of rated Cv)
 ClassVI generally appliesto resilient seated valvesonly.
 Fluid Velocity
 Excessivefluidvelocity can createerosion, andaccelerate
corrosion damage. It alsocontributestonoiselevel and
vibration.
 Valveuserswill generally defineacceptablevelocity in valves
andpipesfor theabovereasons. Liquidvelocity of upto15
ft/sec. iscommon; for gasor steam400ft/sec. or higher,
dependingupon size, isperfectly acceptable.
Noise and Vibration
 Noiseresultsfromtheconversion of themechanical energy of theflowinto
acousticenergy asthefluid passesthrough thevalverestriction.
 Vibration isadirect result of noiseand can createissueswith valvelife.
 OSHA hasdesignated 85-90 Dbaasthegenerally acceptablelimit for
valvesinstalled in most areas.
 Noisecan bereduced through two means, internal at thevalvetrim, and
external such aspipeinsulation or downstreamsilencers.
 Cageguided globevalvesoffer thewidest rangeof noiseand vibration
attenuation solutions.
Rangability
 Rangability isdefined astheratio of minimumto
maximumcontrollable flowrates.
 Equal percent characteristicoffersthebest rangability of
common types.
100

80 Equal Percent

60 Modified Parabolic
% Cv

40 Linear

20 Quick Opening
0
0 20 40 60 80 100
% Open
Flow Direction

 Many valvetypeshaveapreferredflowdirection tominimize

theeffectsof velocity, tocreatethetightest shut-off, andto
optimizetheresponsetoinput signal.
 DeZurik Operation

G lo b e V a lv e s

October 2005
 DeZurik Operation

G lo b e
VHowadolv e s
they work?

- By linear (stroke) action

- A contoured plug is lifted
out of a seat ring to allow
Flow
flow to pass in

- In most (not all) cases

flow comes in
“under the seat”
- Conversely, pushing the
plug down into the seat causes closure

October 2005
 DeZurik Operation

G lo b e
V a
Unbalanced
Trim
/lv e
Balanced s
- Unbalanced has system
pressure acting against
the full area of the seat
Single seated plug styles
are unbalanced
- Balanced has provisions
for offsetting system
pressure
Available in double seated
plug or balanced cage styles

October 2005
 DeZurik Operation

G lo b e
V a &lv
Bodies e s
Bonnets

- Configured as required
to meet valve style and
ANSI Class considerations
- Removable bolted bonnets
retain and/or support the
trim components

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 DeZurik Operation

G lo b e
V3 aWaylv e s for
configurations
Mixing and diverting.

-Temperature control
- Blending

October 2005
 DeZurik Operation

G lo b e Top guided style

V
Trima lv e s
Components

- Stem, plug, seat,

cage (if that style) & Cage guided style
guiding components
- Made of alloy materials
- Optional hardened seating
surfaces when required

October 2005
Noise and cavitation control trims

By directing flow through a series

of staged drops, these trims
eliminate cavitation in liquid flow
and provides multiple pressure
breakdown for noise attenuation
 DeZurik Operation

Ro ta ry C o n tro l
V a lv e s

October 2005
 DeZurik Operation

Ro ta ry
CDesign
o n& Construction
tro l
VANSI
a lv e Face
& ISA s to Face

October 2005
 DeZurik Operation

a r y C o n t r o l V a lv e s
V ported valves:
Uses a ball segment that is
Always in contact with the seat.

Up to 100:1 rangability.

Eccentric type:
Uses a plug that cams away
from the seat during opening

Ideal solution for erosive services

Such as slurries and steam.

Available with a range of flow

capacities.

October 2005
 DeZurik Operation

High performance
Butterfly Valve
Ideal economic choice for
larger line sizes

50:1 Rangeability

Modified equal percent flow

Characteristic

Fast accurate response to

Control signal

October 2005
Actuators
 Theactuator providesthemusclefor thecontrol valveandis
responsiblefor movingthevalvecontrol element tothe
requiredstrokeposition.
 Springdiaphragmactuatorsarethemost widely recognized
andusedby control valvesuppliers.
 Reverseacting; fail closed and direct acting; fail open.
 Simplisticdesign ,fewmovingparts, and easy to maintain.
 Doubleactingpistons
 Smaller, lighter, and lessexpensivethan diaphragm.
 Fail in last position.
Actuators
Accessories
 Positioners–pneumaticinput 3-15psi
Electro-pneumatic4-20ma
(HART, Fieldbus, Profibus)
 Limit switches
 Position feedback
Review material

ISA Practical GuidePublications

Control Valves
Manufacturersdataandguides.

Al Holton
Nor’ East Controls
al@ allagashvalve.com
508-864-5984
Control Valve Noise
 What is noise? Noise is unwanted sound.
 Irritant to most peopleresultingin circulatory problems.
 Overexposurecan result in hearingloss.
 Limitsset by OSHA, Occupational Safety andHealth Act; 90
dBA.
 Noisegeneratedby control valvescan causedamage.
 Threemajor formsof valvegeneratednoise:
 Mechanical
 Hydrodynamic
 Aerodynamic
Hydrodynamic Noise
 Liquidflownoise, cavitation noise, andflashingnoisecan be
generatedby theflowof aliquidthrough avalveandpiping
system.
 Of thethreenoisesources, cavitation isthemost serious
becausenoiseproducedin thismanner can beasign that
damageisoccurringat somepoint in thevalveor downstream
piping. Select cavitation elimination or containment trim.
 Prediction techniquesfor subcritical liquidflowandcavitation
noiseareavailable.
 Flashingnoiseisnot easily predictableandisnot often a
problem. Hardfacedtrimsareoften recommended.
Ratings
 Pressureandtemperatureratingsfor pressurecontainment
partshavebeen establishedfor themorecommon materialsby
theAmerican National StandardsInstitute(ANSI). Class150,
300, 600, 900, 1500, 2500, 4500, andSpecial Classoptions.
 Sincemost materialshaveareduction in allowableworking
stressat elevatedtemperatures, thepressuretemperaturerating
must beconsideredin thechoiceof materials. Chrome-moly,
carbon steel, stainlesssteel
Trim Materials
 Valvetrimmaterial selection isgenerally influenced by thefactorsof
corrosion, erosion, wear, galling, pressuredrop, and temperature, instead of
pressurecontainment considerations.
 Commonly used materialsare304, 316, 416, 440, and 17‑4precipitation
hardened (PH) stainlesssteels. Other materialssuch asnickel alloys(i.e.
Hastalloy, Monel… ), and cobalt chromiumalloy (i.e. Stellite), are
sometimesrequired.
 A common practiceisto useabasematerial, such as316stainlesssteel,
faced with cobalt chromiumalloy at pointsof expected wear such asseating
surfacesand/or guideposts.
 Material selection isoften limited by valvedesign. Turned contoured plugs
and seat ringscan often bemadefromreadily availablebar stock. Cast
componentswith complex geometricshapesmay haveamorelimited range
of offering.
Materials of Construction
 Materialsof construction arevery important in control valve
design sincecontrol valvesarerequiredtohandleall typesof
fluids.
 Fluidscan vary fromclean, dry air tocorrosivechemicalsat
temperaturesrangingfromnear absolutezerotowell above
1000degreesFahrenheit andpressuresfromnear vacuumto
50,000psigor higher.
 Most control valvematerialscan beplacedin twocategories:
 Pressure containment materials
 valve body, bonnet, bottom flange, and bolting
 Valve trim materials; seats, plugs, guides, stems, shafts.
Pressure Containment Materials
 Carbon steel isthemost common material for themajority of
applications.
 Other materialscommonly usedincludechrome-moly,
stainlesssteel andcast iron.
 Someservicesrequiretheuseof exoticalloys, high nickel
content metalssuch as, monel, hastelloy, even inconel, duplex
stainlesstowithstandcorrosivefluids.
 Somemanufacturersoffer linedor compositevalvestohandle
lowpressurecorrosiveservices.
End Connections
 Control valveendconnectionsmay beclassifiedasfollows;
threaded, butt-weld, socket weld, flanged, andflangeless.
 Threadedconnections(femaleNPT thread) arecommon in
valvesizes1 inch andsmaller andaresometimesusedfor
control valvesupto2inches.
 Weldedendsarecommon wherehigh pressure, high
temperature, or highly toxicfluidsareencountered. Care
shouldbetaken toseethat thevalvebody material specifiedis
compatiblewith theadjoiningpipematerial.
End Connections (cont.)
 Flangedendglobebodiesgenerally conformtothe
standardizedface-to-facedimensionslistedin ANSI B16.10,
with theexception of Saunderstypes(weir or diaphragmtype)
andanglebodies.
 The flange rating is determined by the type of service, required
material, maximum pressure, and the maximum fluid temperature.
 Flangelessendconnectionshavenoflangeconnection aspart
of thevalvebody andaresimply boltedor clamped between
theadjoininglineflanges.
 Face-to-face dimensions for these valves are listed in ISA S.75.04
(1979).
 Singleflangedesignsavailablein butterfly valves.
Actuator Bench Range
 Asit relatestospringdiaphragms, theactuator bench rangeis
theoperatingair pressurerangeunder noloadfor therated
stroke; i.e. 3-15psi, 6-30psi, 10-24psi.
 Increasingair pressuremovestheactuator through it’ srated
stroke; i.e. theactuator startsmovingat 3psi andcomestoits
ratedstrokeat 15psi.
 Air supply = in apneumaticactuator it istheminimum
pressuresuppliedtothecontrol valveactuator toobtain the
necessary performance; i.e. shut-off, speedof response, full
rangeof stroke.
Instrument Control Signal
 Generally apneumaticor electronicimpulsesent from
acontroller tothecontrol valve; generally through a
valvepositioner toposition thevalvefor thedesired
control objective.
 Themost commonly usedinstrument signalsare
analog3-15psi or 4-20milliamp. (10-50ma)
 Analogcontrol signalsandpoint topoint
communicationsarebeingreplacedby digital based,
smart devices, communicatingon plant wide
networks: AnalogtoHART toFF networks.
Seat Leakage
 Thecontrol valveplugisthemovingcomponent of thevalve
which throttlesflowby positioningitself within theseat orifice
andshutsoff flowby contactingtheseat.
 Leakageasmeasuredduringfactory testingisconsideredtobea
qualitativevalueof seat leakage, even though quantitative
measurementsarethecriteriafor testing.
 Installedleakagenormally exceedsthat measuredduringfactory
testing. Processisoften morehostilethan test media.
 Generic Control Valve Types
Features Comparison
Double Single Bal. Split Eccentric
Key Features Seat Seat Trim Angle Y Pattern 3- Way Body Ball Butterfly Plug
Capacity 1 1 1.2 1 to 2 1.5 0.7 1 3 3.2 1.3
Shut Off % Rated Cv 0.5 <0.01 0.01 0.01 0.01 N/A 0.01 0 0 or1 0.01
Cv Ratio 50 50 50 50 50 50 50 100 25 100
Cavitation G S G S P S S P P S
Noise G S G S P S S P P S
High Pressure/High DP G S V.G. S S P S P P S
High Temp/Low Temp S S V.G. S G S S P P G
Erosion/Slurry S S P G S S G S P G
Corrosion S G P S S S G S S G
Maintenance S G S S S S V.G. G G G
Cost 1.25 1 1.12 1.2 1.5 1.8 0.97 0.73 0.4-0.7 0.83
RAVEN Trim Design Features
 MultipleFlowInlets
 Resist “Pluggage”
educing and
 Rapid Reduction of Velocity ttenuating
 FlowPath
elocity
 Thin Wall Design
 Maximizestorturouspath rosion and
 Assuresuniformvelocity control
 Open FlowPath oise
 PermitsFlowBalancing
 Resists“Pluggage”
 Relief Points
 Providesalternatepathsif blockagedoesoccur
 MultipleFlowOutlets
 Eliminatesjet impedance
Lower noise
200:1


 Reducesbody impingement
 Reduceswear
 Noise Reduction
Comparison
Noise Comparison
115
Sound Pressure Level (dBA)

110
At thesameflowrate, CopesVulcan noiselevels
105
areapproximately 6dBalower than the
100
competitorslabyrinth trimdesign.
95
Raven
90
tor Competitor Thisisduein part to agreater number of inlet
85
pathsprovidingamoreuniformflowpath through
50 300
80
0 50 100 150 200 250 300
thelabyrinth groves.
Upstream Pressure (psig)

Flow Rate Comparison Noise Comparison

18000 115
16000
110
14000
Sound Pressure Level (dBA)

105
12000
Flow Rate (scfh)

10000 100
8000 95
Raven Raven
6000
Competitor 90
4000 Competitor
85
2000
0 80
0 50 100 150 200 250 300 0 50 100 150 200 250 300
Upstream Pressure (psig) Upstream Pressure (psig)

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 DeZurik Operation

Ro ta ry
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V a lv e s

October 2005