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Valve Sizing - Flow Rate PDF
Valve Sizing - Flow Rate PDF
Nominal size DN
kv values
p = p1 - p2
T1
p1 +
T2
p2
6DN
2DN
Medium:
,pv,
p = p1 p2 =
)2
(
A nom. size
2
In automated engineering, process quantities are controlled by changing the flow quantity Q . The
pressure difference is simply a means to this end (valve authority). As a parameter for flow capacity,
3
one therefore has the k v value as the water quantity kv in m / h at a pressure difference of
kv
0
)2
(
A nom. size
2
or
2 p0 Anom. size 2
)
(
kv
0
The last equation gives the relation between the pressure loss coefficient (with relation to the
nominal size) and the k v value.
The rule of thumb usually applied:
kv =
Q
p
is only correct for water (20 degrees C). More correct is the formulation:
kv =
p0
Q
p
0
or
Q=
0
p
kv
p0
This equation means that the flow quantity doubles when the pressure difference is increased four
times.
The equation above is only correct for non-compressible media such as water. Gaseous and
vaporous media are compressible, so one must account for density changes through the flow path
using a correction factor, the so-called expansion factor Y. If one uses the inlet density 1 and the
flow volume Q 1 at the valve entrance, one arrives at the following equation:
kv =
1
p0
1
Q1
p
Y
0
Due to mass conservation during passage of the valve, the inlet flow mass is equal to the outlet flow
mass. Due to the pressure-dependent density, the flow volume on the inlet side ( Q 1) is less than on
&
the outlet side ( Q 2 ). It is a good idea to use the flow mass m = W = W1 = W2 .
kv =
1 W 1
p0
p
0 1 Y
The expansion factor is less than 1. Therefore, greater k v values are required than for liquids with
the same operating and materials data.
Due to additional limiting conditions (cavitation, speed of sound), this correction factor is not the only
one. The equations required are contained in Parts 2-1 and 2-2 of the DIN IEC 534 standard. Due to
the non-perspicuous form used there, the unit-independent form has always been selected here, and
one basic equation is used for liquids and gases/vapors.
kv =
1
1
p0
,
Q1
FP FR Y
p
0
p p max
with
0 = 1000 kg / m 3
and
p0 = 1 bar
The correction factors FP , FR and Y take into account the following influences:
Flow limitation: pmax , velocity throttling point
The influence of pipeline geometry: FP
Expansion factor: Y
Viscosity influence: FR
k v / DN ), i.e. for butterfly valves and ball valves. Linear control valves can usually be calculated
well with FP = 1.
FP =
Fp=1
p1
DN
p2
DN
DN
Fp<1
p1
p2
DN
DN1
DN2
FP 1
kv
< 0.02
2
if DN / D1 or DN / D 2 > 0.8 and DN
k v (m / h) and DN (mm)
Generally
FP = 1-
0
2 p0
(B1 + 1 B2 + 2) (
2
DN
4
otherwise
DN 4
)
DN1
DN 4
B2 1 (
)
DN2
B1 1 (
1
DN 2 2
((1 (
) )
2
DN1
DN 2 2
2 ((1 (
) )
DN2
1
1.0
0.9
0.8
Type, kv/DN ^2 [m ^3/h/mm ^2]
0.7
0.6
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1.0
The corresponding critical pressure difference pmax is calculated according to medium type.
Q, W
kv=const.
p1=const.
pmax
Liquids
pmax
Gases/vapors
p
Non-compressible media (liquids)
pmax =
FLP 2
(p1 FF pv )
FP 2
FLp = FL
FLp =
,if FP = 1
FL
kv 2
0
1+
)
FL2 (B1 + 1) (
2 p0
2
DN
4
FF = 0.96 - 0.28
pv
pc
,if FP < 1
The FL value is a valve parameter. It is referred to as the pressure recovery factor. Linear control
valves have the highest FL values (at 0.9 to 0.95) and therefore larger, more useful critical pressure
differences for flow limitation than other valve types.
This value must be corrected (FLP ) if fittings are present and FP < 1 is therefore the case.
pmax = xTP
p1
1.4
xTP = xT
,if
Fp = 1
xT
FP 2
xTP =
1+
kv
0 8
)2
xT (B1 + 1) (
2 p 0 9
2
DN
4
, if FP < 1
The xT value is a valve parameter. It is designated as the critical pressure ratio for flow mass
limitation. Linear control valves have the highest xT values (at 0.68 to 0.77) and therefore larger,
more useful critical pressure differences for flow limitation than other valve types.
This value must be corrected ( x TP ) if fittings are present and FP < 1 is therefore the case.
p = Carnot
uvc 2
2
The velocity energy is obtained approximately using the Bernoulli equation and ignoring pressure
losses from inlet 1 to the throttling point vc.
p
= FL2
p1 - pvc
When flow limitation has just been reached, the pressure in the trottling point is equal to the critical
pressure
A higher pressure recovery means that at a fixed velocity uvc in the throttling point and a fixed inlet
p1 , the pressure difference p is small or the pressure p2 is great. This means the same
as with a small FL value, but also the same as with achieving flow limitation at lower pressure
pressure
laminar
turbulent
The so-called valve Reynolds' number is a judgement measure for whether a flow is turbulent.
This dimensionless parameter combines
the geometry dimensions (throttle diameter dependent on the k v value, the FL value and the
valve form factor Fd )
the kinematic viscosity
and the flow quantity Q
Such Reynolds' numbers are used in flow technics for pipe and split flows, for example.
Valve Reynolds' number:
Re =
p0 14 Q Fd
p0 14
Q Fd
25 / 4
(
)
)
= 1. 34 (
1/ 2
0
0
kv FL
kv FL
The valve form factor Fd accounts for the geometric form of the throttling point in the form of the
hydraulic diameter hyd as the diameter d0 (throttle cross-section area converted into circle surface
area). The hydraulic cross-section is defined as the quadruple throttle cross-section area divided by
the circumference of the jet emitted by the throttling point. It characterizes the ratio of the jet surface
area (when one also considers the jet length) to the flow cross-section. The total resistance force
resulting from the transverse stresses in effect in the flow (viscosity), and therefore the pressure loss,
is dependent upon this.
Example: Pipeline (diameter
d0 ):
d0 2
4
= d0
dh =
d0 L
4
dh =
Fd =
dh
=1
d0
Sb , s << Sb , microvalve):
4 s Sb
= 2s
2 Sb
Fd =
s
Sb
For valve Reynolds' numbers greater than 10,000, experience shows that turbulent flow conditions
are always present. The correction factor FR here is always 1.
Below 10,000 there is an interim range to lower FR values, before laminar flow conditions set in.
Because the pressure loss for laminar flows is
In contrast to older versions of DIN IEC 534 P. 2-1, the correction factor procedures for the constant
2
K = f(k v / DN )
which approximates the measurements.
Equations for FR
turbulent range
interim range
FR(Re) = 1,
for Re
10000
1
Re 1 + log(Re) + K
FR(Re) = (
)
10000
for Re < 10000 ,
minimum laminar range
FR(Re) = 0.026 K Re / FL
if FR
1:
= 1
Constant K
kv
0.0137
(kv [m 3 / h], DN [mm])
DN2
kv
> 0.0137
2
(kv [m 3 / h], DN [mm])
DN
2
kv 3
K = 1+138 (
)
DN2
K = 0.0016
1
kv 2
(
)
DN2
One sees that greater corrections are necessary for smaller specific flow outlets (K- > 1) than for
higher flow outlets.
The correction factor can only be determined iteratively.
Y(x) = 1
Compressible media (gases, vapors)
Y(x) = 1-
x
2
3 xT 3 ,
Y(x) = 1
1
x
2
,
Re 10000
Re < 10000
x = (p1 - p2 ) / p1
Expansion factor Y
xT=0.5
Y(x) for Re < 10000
xT=0.75
xT=0.95
0.9
0.8
0.7
0.6
0.0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1.0
Adaption
Initial value 100% FL-value
xT-value
capacity load
Model
type
DN
kvs
Re calculation
i
FPcalculation
FR=1
FRcalculation
kv value basic
calculation
FP=1
i+1
kv,i+1/kv,i
between 0.95
and 1.05
no
yes, kv=kv,i+1
kv
kvs = kv max SF
Valve parameters such as FL , x T are dependent on valve type, k vs value and the nominal size DN ,
so that iterations which the user does not notice occur during calculation in the background in the
valve sizing program.
To fulfill the prescribed control task, the condition
Ra:
: Rangeability value
must also be fulfilled while also observing a characteristic form (e.g. linear, of equal percentage).
Typical rangeabilities can be taken from the following table.
Linear
Same
percentage
30:1 to 50:1
(contour)
0:1 to 50:1
(contour)
Microvalve
5:1 to 50:1
(contour)
50:1 (contour)
50:1
(cam disk)
Butterfly valve
Plug valve
Root funktion
5:1
50:1
(cam disk)
150-200:1
For linear control valves with k vs > 0.01 m / h , linear and same percentage characteristic forms
can be implemented by adapting the ball contour.
3
k vs value range, the flow usually changes to a laminar condition, so that the rangeability is
Q ~ k v2
usually squared (from kv FR Re and Q ~ Re , it follows that
).
the lowest
Without a cam disk in the positioner, butterfly valves have a tendency to be same percentage. Plug
valves tend toward linear flow characteristics, with the commonly propagated rangeabilities of > 50:1
being heavily exaggerated because the characteristic tolerance according to DIN IEC 534 P. 2-4
cannot be fulfilled.
100
lin.
80
60
40
4
3
2
1
0
glp.
20
0
0
10
20
30
40
50
60
70
80
90
100
Rangeabilities (microvalve)
Rangeability
0.000
0.002
0.004
0.006
0.008
0.010
kv / kv (90 degrees)
1.00
450
300
0.01
150
0.01
0
10
20
30
40
50
60
70
80
90
kv / kv (70 degrees)
450
1.000
300
0.100
150
0.010
0.001
0
10
20
30
40
50
60
70
80
90
The correct nominal valve size DN is obtained from a maximum authorized limit velocity 2limit in the
valve outlet cross-section. These limit values are based on values gained by experience, but they
can also be changed by the user in the valve sizing program.
The average velocity for a selected nominal valve size is (W: mass flow):
u2 =
DN2 2
4
The required nominal valve size DNerf can be determined by converting the equation above:
DNerf =
u2 limit 2
4
2 = 1
u
= 10 m / s
always: 2limit
> p v ):
Density:
u2limit = 1 m / s
u2 max [m/s]
for cavitation
10
9
8
7
6
5
4
3
2
1
0
0
p2-pv [bar]
Limit values for gases and vapors
u2limit = 0.3 c 2
Speed of sound
c2 =
c 2 in valve outlet:
p2 / 2
with diffuser-type pipe extensions behind the valve, the p 2 pressure used internally in the
program ( p2valve ) is less than the p2 pressure in the large pipeline.
u2
u2limit
Proportion evaporated
p1 - pv
+ h1'-h2')
1
xd2 =
100 %
h2 '' h2 '
(
v 2 '' (wet vapor) for water from approximate equation (vapor chart)
Outlet density
2 =
1
xd2
1
xd2
(1
) +
v 2''
100% 1 100%
p v , p1 p v )
ulimit = 60 m / s
Proportion evaporated
p1 - pv
xd1
+ h1'-h2'+(h1'' h1')
)
1
100%
xd2 =
100 %
h2'' h2 '
(
the two phase flows handled separately. This yields two individual
vapor/gas), which are added.
values (
l: Liquid,
kv, fl =
kv, d, g =
p
0
0
fl
W (1-
xd, g, 1
)
100%
fl
p0
d,g,1
0
p
xd, g, 1
100%
d, g, 1
FLP 2
) (p1 FF pv )
FP
1
,
(FP FR Y), fl
p (
1
,
(FP FR Y), d, g
p xTP
p1
1. 4
The added k v value must now be multiplied by an additional safety factor cor,2ph , because the two
phases do not flow independently of each other within the valve and a velocity compensation
between the "fast" gas or vapor phase and the "slow" liquid phase takes place.
A targeted correction can be achieved with the Sheldon and Schuder procedure.
Volume content:
: v 1'=
(
1 xd, g1 xd, g, 1
)
+
fl, 1
d, g, 1
Vd, g
Vd, g + Vfl
1
Avc
0
with A vc = kv FL (
)2
Mp = 0.35 + 0.65
ADN
2 p0
Ma = 0.75 + 0.5 x for x 0.5 with x = (p1 - p2 ) / p1
Ma = 1
for x > 0.5
Fm from diagram
1
0.9
0.8
0.7
0.6
0.5
0.4
0.3
0.2
0.1
0
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
This function is not integrated at this time, but will definitely be contained in later program versions.
SAMSON AG, working in cooperation with flow technics department of the TU Hamburg-Harburg (L.
Friedel, Dr. Engineering), has carried out detailed investigations on the valve flow behavior of
water/steam systems. This has resulted in the development of a calculation procedure which is
certainly the most accurate available today, but which will also be available in a later version.
At present, the program user must create 2 files (e.g. 60dg.pos and 60fl.pos) for each measurement
point for the liquid and the gaseous/vaporous parts. He then obtains 2 k v values which must be
added together. 1.35 should be used in the interim as the correction factor
Fcor,2ph .
values
-6
-7
value range of 10
-5
Reynolds' number RE
Turbulent conditions (FR
differences.
values below 10
-5
smaller than 1 m, even when seat holes of 1 or 2 mm are used. This cannot be practically
implemented for reasons of manufacture or can only be implemented without long-term stability
(wear).
100
10
0.1
1E-07
1E-06
1E-05
1E-04
1E-03
1E-02
1E-01