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6.

6 Capacity Testing
(Copyright ISA 1996, reprinted with permission of ISA, The Instrumentation, Systems, and Automation Society.
Standard formatted for publication in this handbook by A. Bálint, 2005)

INTRODUCTION e. Piping geometry factor, FP


f. Pressure drop ratio factor, XT and XTP
The “Control Valve Capacity Test Procedure” is covered by
Instrumentation, Systems, and Automation Society’s (ISA’s) This standard is intended for control valves used in flow
Standard S75.02-1996. The international equivalent of these control of process fluids and is not intended to apply to fluid
U.S. standards are IEC 60534-2-1, “Industrial Process Con- power components as defined in the National Fluid Power
trol Valves, Part 2-1: Flow Capacity Sizing Equations for Association (NFPA) Standard T.3.5.28-1977.
Fluid Flow under Installed Conditions,” and IEC 60534-2-3,
“Industrial Process Control Valves, Part 2-3, Flow Capacity
Test Procedure.” The equations in the international editions 2. PURPOSE
are essentially equivalent to those in the U.S. standards, with
the exceptions of using metric units. The purpose of this standard is to provide a procedure for
A revision of the ISA standard is anticipated in the near testing control valve capacity and related flow coefficients
future, and for this reason only the front part of S75.02-1996 for both compressible and incompressible fluids. This stan-
is reprinted below. The reader is advised to refer the revised dard also provides a procedure to evaluate the major data.
standard (when published) for the test procedures and calcu-
lations. Meanwhile, Section 6.15 can be used for all valve
sizing applications, while Section 6.14 provides all the infor- 3. NOMENCLATURE
mation needed for valve noise calculations.
The reader should also note that in the ISA test (For the actual control valve sizing equations for both com-
procedure the pressure taps are not located at the in- and pressible and incompressible fluids, the reader should refer
outlets of the control valve, but two pipe diameters upstream to Section 6.15)
and six pipe diameters downstream. Therefore, the pressure
differential measured during the test is the sum of the valve
pressure drop (∆Pv) and the drop through eight pipe diame- 4. TEST SYSTEM
ters’ length of straight piping (∆Pp). This can introduce errors,
if the pressure drop in the pipe exceeds 5–10% (∆Pp /(∆Pp + 4.1 General Description
∆Pv) > 0.1).
This section is reprinted from “Control Valve Capacity A basic flow test system as shown in Figure 6.6a includes
Test Procedure,” ANSI/ISA-S75.02-1996, with permission of
the copyright holder, ISA, The Instrumentation, Systems, and a. Test specimen
Automation Society, 67 Alexander Drive, P.O. Box 12277, b. Test section
Research Triangle Park, NC 27709. c. Throttling valves
d. Flow-measuring device
e. Pressure taps
f. Temperature sensor
1. SCOPE
4.2 Test Specimen
This test standard utilizes the mathematical equations out-
lined in ANSI/ISA-S75.01, “Flow Equations for Sizing Con- The test specimen is any valve or combination of valve, pipe
trol Valves,” in providing a test procedure for obtaining the reducer, and expander or other devices attached to the valve
following: body for which test data are required (Figure 6.6a). Modeling
of valves to a smaller scale is an acceptable practice in this
a. Valve flow coefficient, Cv standard, although testing of full-size valves or models is pref-
b. Liquid pressure recovery factors, FL and FLF erable. Good practice in modeling requires attention to signif-
c. Reynolds number factor, FR icant relationships such as Reynolds number, the Mach number
d. Liquid critical pressure ratio factor, FF where compressibility is important, and geometric similarity.

1150

© 2006 by Béla Lipták


6.6 Capacity Testing 1151

Symbol Description

Cv Valve flow coefficient


d Value inlet diameter
D Internal diameter of the pipe
Fd Valve style modifier
FF Liquid critical pressure ratio factor, dimensionless
Fk Ratio of specific heats factor, dimensionless
FL Liquid pressure recovery factor of a valve without attached fittings, dimensionless
FLP Product of the liquid pressure recovery factor of a valve with attached fittings (no symbol has been identified) and
the piping geometry factor, dimensionless
FP Piping geometry factor, dimensionless
FR Reynolds number factor, dimensionless
Gf Liquid specific gravity at upstream conditions (ratio of density of liquid at flowing temperature to density of water
at 15.6°C [60°F]), dimensionless
Gg Gas specific gravity (ratio of flowing gas to density of air with both at standard conditions, which is equal to the ratio
of the molecular weight of gas to the molecular weight of air), dimensionless
K Ratio of specific heats, dimensionless
m The number of similar flow paths (i.e., m = 1 for single-ported valves, m = 2 for double-ported, etc.)
N1, N2, etc. Numerical constants for units of measurement used
p1 Upstream absolute static pressure, measured two nominal pipe diameters upstream of valve-fitting assembly
p2 Downstream absolute static pressure, measured six nominal pipe diameters downstream of valve-fitting assembly
∆p Pressure differential, p1 − p2
pv Absolute vapor pressure of liquid at inlet temperature
q Volumetric flow rate
qmax Maximum flow rate (choked flow conditions) at a given upstream condition
Rev Valve Reynolds number, dimensionless
T1 Absolute upstream temperature (in K or degrees R)
x Ratio of pressure drop to absolute inlet pressure (∆p/p1), dimensionless
xT Pressure drop ratio factor of the valve without attached fittings, dimensionless
xTP Value of xT for valve-fitting assembly, dimensionless
Y Expansion factor, ratio of flow coefficient for a gas to that for a liquid at the same Reynolds number, dimensionless
ν (nu) Kinematic viscosity, centistokes

Subscripts:
1. Upstream conditions
2. Downstream conditions

Temperature Test Test


sensor specimen section
Downstream
throttling
Flow valve

Source
Upstream Flow
throttling sensor
valve
Pressure taps

FIG. 6.6a
Basic flow test system.

© 2006 by Béla Lipták


1152 Control Valve Selection and Sizing

TABLE 6.6b
Piping Requirements, Standard Test Section
Standard Test
A* and ** B C D Section Configuration

At least 2 nominal pipe 6 nominal pipe At least


B Pressure C
18 nominal pipe diameters of diameters of 1 nominal pipe taps
Flow
diameters of straight pipe straight pipe diameter of
straight pipe straight pipe Test
specimen***
A D

*Dimension “A” may be reduced to 8 nominal diameters if straightening vanes are used. Information concerning the design of straightening vanes can
be found in “ASME Performance Test Code PTC 19.5-1972, Applications, Part II of Fluid Meters, Interim Supplement on Instruments and Apparatus.”
**If an upstream flow disturbance consists of two ells in series and they are in different planes Dimension “A” must exceed 18 nominal pipe diameters
unless straightening vanes are used.
***See Section 4.2 for definition of the test specimen.

4.3 Test Section ment shall be calibrated as frequently as necessary to main-


tain specified accuracy.
The upstream and downstream piping adjacent to the test
specimen shall conform to the nominal size of the test spec-
imen connection and to the length requirements of Table 6.6b. 4.6 Pressure Taps
The piping on both sides of the test specimen shall be
Schedule 40 pipe for valves through 250 mm (10 in.) size Pressure taps shall be provided on the test section piping in
having a pressure rating up to and including ANSI Class 600. accordance with the requirements listed in Table 6.6b. These
Pipe having 10 mm (0.375 in.) wall may be used for 300 mm pressure taps shall conform to the construction illustrated in
(12 in.) through 600 mm (24 in.) sizes. An effort should be Figure 6.6c.
made to match the inside diameter at the inlet and outlet of
the test specimen with the inside diameter of the adjacent
piping for valves outside the above limits.
The inside surfaces shall be reasonably free of flaking
rust or mill scale and without irregularities that could cause
excessive fluid frictional losses.
Minimum 2.5 A
recommended
4.4 Throttling Valves 5A

The upstream and downstream throttling valves are used to


control the pressure differential across the test section pres- *
sure taps and to maintain a specific downstream pressure. A
There are no restrictions as to style of these valves. However, A A
the downstream valve should be of sufficient capacity to Size of pipe Not exceeding Not less than
ensure that choked flow can be achieved at the test specimen Less than 50 mm (2 in.) 6 mm (1/4 in.) 3 mm (1/8 in.)
50 mm to 75 mm (2 to 3 in) 9 mm (3/8 in.) 3 mm (1/8 in.)
for both compressible and incompressible flow. Vaporization 100 mm to 200 mm (4 to 8 in.) 13 mm (1/2 in.) 3 mm (1/8 in.)
at the upstream valve must be avoided when testing with 250 mm and greater 19 mm (3/4 in.) 3 mm (1/8 in.)
liquids. (10 in. and greater)

FIG. 6.6c
4.5 Flow Measurement Recommended pressure connection.
* Edge of hole must be clean and sharp or slightly rounded, free from burrs,
The flow-measuring instrument may be any device that meets wire edges or other irregularities. In no case shall any fitting protrude inside
specified accuracy. This instrument will be used to determine the pipe. Any suitable method of making the physical connection is accept-
the true time average flow rate within an error not exceeding able if above recommendations are adhered to. Reference: “ASME Perfor-
±2% of the actual value. The resolution and repeatability of mance Test Code PTC 19.5-1972. Applications, Part II of Fluid Meters,
the instrument shall be within ± 0.5%. The measuring instru- Interim Supplement on Instruments and Apparatus.”

© 2006 by Béla Lipták


6.6 Capacity Testing 1153

Orientation:
TABLE 6.6d
Incompressible fluids—Tap center lines shall be located Allowable Misalignment between the Centerlines of
horizontally to reduce the possibility of air entrap- the Test Specimen and of the Test Section Piping
ment or dirt collection in the pressure taps. Pipe Size Allowable Misalignment
Compressible fluids—Tap center lines shall be oriented
horizontally or vertically above pipe to reduce the 15–25 mm 0.8 mm
1
possibility of dirt or condensate entrapment. ( /2 –1 in.) ( 1/32 in.)
32–150 mm 1.6 mm
Multiple pressure taps can be used on each test section 1
(1 /4 –6 in.) ( 1/16 in.)
for averaging pressure measurements. Each tap must conform
to the requirements in Figure 6.6c. 200 mm and larger 1% of the diameter
8 in. and larger)

4.7 Pressure Measurement

All pressure and pressure differential measurements shall be 5. TEST FLUIDS


made to an error not exceeding ±2% of actual value. Pressure-
measuring devices shall be calibrated as frequently as nec- 5.1 Incompressible Fluids
essary to maintain specified accuracy.
Pressure differential instruments are required in the mea- Fresh water shall be the basic fluid used in this procedure.
surement of the pressure differential across the test specimen Inhibitors may be used to prevent or retard corrosion and to
to avoid additional inaccuracies resulting from taking the prevent the growth of organic matter. The effect of additives
difference of two measurements. Exceptions to this are the on density or viscosity shall be evaluated by computation
procedures in Sections 6.2 and 8.2 for determining maxi- using the equations in this standard. The sizing coefficient
mum flow rates for incompressible and compressible flow, shall not be affected by more than 0.1%. Other test fluids
respectively. (These sections are not included here, the reader may be required for obtaining FR and FF .
is referred to ANSI/ISA-75.02-1996 for guidance in these
procedures.) 5.2 Compressible Fluids

Air or some other compressible fluid shall be used as the


4.8 Temperature Measurement basic fluid in this test procedure. Vapors that may approach
The fluid temperature shall be measured to an error not their condensation points at the vena contracta of the speci-
exceeding ±1°C (±2°F) of actual value. men are not acceptable as test fluids. Care shall be taken to
The inlet fluid temperature shall remain constant within avoid internal icing during the test.
±3ºC (±5°F) during the test run to record data for each spe-
cific test point.
SUMMARY
4.9 Installation of Test Specimen
The international equivalent of this U.S. standard are IEC
The alignment between the centerline of the test section 60534-2-1, “Industrial Process Control Valves, Part 2-1:
piping and the centerline of the inlet and outlet of the test “Flow Capacity Sizing Equations for Fluid Flow under
specimen shall be as listed in Table 6.6d below: Installed Conditions,” and IEC 60534-2-3, “Industrial Pro-
When rotary valves are being tested, the valve shafts shall cess Control Valves, Part 2-3, Flow Capacity Test Procedure.”
be aligned with test section pressure taps. A revision of the Instrumentation, Systems, and Auto-
Each gasket shall be positioned so that it does not pro- mation Society standard is anticipated in the near future, and
trude in the flow stream. for this reason only the first five sections of S75.02-1996
were presented here. The reader is advised to refer the revised
ANSI/ISA-75.02-1996 standard (when published) for Sec-
4.10 Accuracy of Test
tions 6 to 10 for the test procedures and calculations. Mean-
2
Valves having an N3Cv /d ratio of less than 30 will have a while, Section 6.15 can be used for all valve sizing applica-
calculated flow coefficient, Cv , of the test specimen within a tions, while Section 6.14 provides all the information needed
tolerance of ±5%. for valve noise calculations.

© 2006 by Béla Lipták

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