Control Valves: Rolta Academy:Engineering Design Services

Rolta Academy:Engineering Design Services
CHAPTER 10
CONTROL VALVES
10.0 INTRODUCTION
Estimates reveals that a substantial portion approximately 8-10% of total
capital expenditure of the chemical process industry is used for the
procurement of valves. In terms of the number of units also, valves exceed
any other piping component. Hence proper thought is given for selection of
valves. The first step in selection is to determine exactly what function the
valve is expected to perform after it has been installed. Valves are installed on
equipment/piping to perform any one of the following functions:
1.isolation
2.regulation
3.nonreturn
4.Special purpose.
1.0 ISOLATION
GATE
BALL
PLUG
PISTON
DIAPGHRAM
BUTTERFLY
PINCH
2.0 Regulation
Globe
Neddle
Butterfly
Diapghram
Piston
Pinch
3.0 Non return
Check valves
4.0 Special purpose
Multi port
Flush bottom
Float
Line blind
Knife gate.
What are Ball Valves?
Instrumentation Engineering

A ball valve (like the butterfly valve, one of a family of valves called quarter
turn valves) is a valve that opens by turning a handle attached to a ball inside
the valve. The ball has a hole, or port, through the middle so that when the
port is in line with both ends of the valve, flow will occur. When the valve is
closed, the hole is perpendicular to the ends of the valve, and flow is blocked.
The handle position lets you "see" the valve's position.
Ball valves are durable and usually work to achieve perfect shutoff even after
years of disuse. They are therefore an excellent choice for shutoff applications
(and are often preferred to globe valves and gate valves for this purpose).
They do not offer the fine control that may be necessary in throttling
applications but are sometimes used for this purpose. The body of ball valves
may be made of metal, ceramic, or plastic. The ball may be chrome plated to
make it more durable.
There are three general body styles of ball valves: split body, top entry, and
welded. There are three general types of ball valves: full port, standard port,
and reduced port.
A full port ball valve has an oversized ball so that the hole in the ball is the
same size as the pipeline resulting in lower friction loss. Flow is unrestricted,
but the valve is larger.
A standard port ball valve is usually less expensive, but has a smaller ball and
a correspondingly smaller port. Flow through this valve is one pipe size
smaller than the valve's pipe size resulting in slightly restricted flow.
In reduced port ball valves, flow through the valve is two pipe sizes smaller
than the valve's pipe size resulting in restricted flow.
A trunnion ball valve has a mechanical means of anchoring the ball at the top
and the bottom.
Manually operated ball valves can be closed quickly and thus there is a
danger of water hammer. Some ball valves are equipped with an actuator that
may be pneumatically or motor (electric) operated. These valves can be used
either for on/off or flow control. A pneumatic flow control valve is also
equipped with a positioner, which transforms the control signal into actuator
position and valve opening accordingly.

Fig 10.1 Ball Valve
What are Butterfly Valves?
A butterfly valve is a particular type of valve that uses either a circular vane or
a disc as the shut-off mechanism. Butterfly valves have a quick
opening/closing quarter-turn mechanism that is used to control the flow of
liquid through a piping system. They typically pivot on axes perpendicular to
the direction of flow inside the flow chamber. Compared with ball valves,
butterfly valves do not have pockets to trap fluids when the valve is in the
closed position. Butterfly valves are frequently used as throttling devices,
controlling the levels of flow in various positions: entirely closed, entirely open
or partially open. They can control various substances of air, liquid or solid
currents and are situated on a spindle that allows for flow in a single
direction.Butterfly valves are offered in many sized diameters, resulting in
different flow rates. Smaller valve assemblies may be used where space is
limited. Knowing the pipe dimensions, desired flow rate and material is
important when considering a valve investment. Installation time is typically
low compared to some other types of valves, and additional parts are
unnecessary to work and maintain the valve.
Butterfly valves have a lever that allows the operator to open or close the
valve to control the flow. These valves are part of a family known as rotary
valves, which are defined by the quarter turn that is used to move from the
open to closed position and vice versa. This results in a lower surface friction,
which means that these valves can be smaller than others and still operate
efficiently.Butterfly valves are available in numerous closure types and body
configurations, depending on the type of flow control needed. These types of
valves are commonly composed of metals, like aluminum and stainless steel,
but also can be made from various plastics. One kind, flange butterfly valves,
can be mounted between flanges. Another, lug butterfly valves, uses metal
inserts that are attached to the valve's boltholes. Using an independent set of
bolts for each flange, this valve assembly is fixed between two flanges.
Finally, wafer style butterfly valves are the cheapest and most popular type of
butterfly valves because of their simplicity and ease of use. Butterfly valves
are used in many food transporting and chemical plants where controllable
product flow is required. Other specific industries include HVAC, tertiary
petroleum recovery and industries that use high-pressure water. When
properly used, butterfly valves offer many benefits. First of all, they are lower
priced than many other types of valves, and generally have a longer life cycle.
Butterfly valves are easy to maintain, are lightweight and compact and are
able to handle a wide range of temperatures. These valves are also very
reliable because of their tight shut-off, reducing the amount of leakage. One of
the problems with butterfly valves, however, is that their design makes it
difficult to efficiently and thoroughly clean all residual contaminants. Also,
these valves are not good for use with highly abrasive or corrosive materials,
because the disc can be easily eroded. Overall, butterfly valves are one of the
fastest growing types of valves in the industry.
Fig 10.2: Butterfly valve

What are Check Valves?
Check valves, also referred to as "non-return" or "one-way directional" valves,
are very simple valves that allow fluid, air or gas to flow in only one direction.
When the fluid moves in the pre-determined direction, the valve opens. The
moveable portion of the valve prevents any backflow. A swinging disc, ball,
plunger or poppet moves out of the way of the original flow. Since these
devices are slightly larger than the through hole, the pressure of backflow will
cause them to tightly seal, preventing reversal of flow. Gravity or a spring
assists in the closing of the valve.
Check valves are indispensable in every area of life. Domestically, they are
found in devices such as faucets, toilets and dishwashers. Without them,
fresh water would be impossible and common plastics would be unheard of.
Industries use them to control flows of all typesfrom the thinnest gas to
radioactive materials, from molten metal to highly corrosive materials. Check
valves can range in size from less than an inch in diameter to 30 feet across.
The simplest check valves can be purchased at the local hardware store, but
they may also be precision-designed for highly sophisticated systems.
As aforementioned, check valves use different means of preventing backflow.
Swing disc valves are typically used with liquids, such as slurries, that can
easily damage the valve seat. They may be installed either vertically or
horizontally, but a lever and counter-balance is recommended when vertically
installing swing disc valves. Ball check valves use a ball with a small hole in

Fig 10.3 Check Valve
the middle, which can be either free-floating or spring-loaded. These valves
have a wide variety of applications. They are more resistant to plugging than
other valves, and thus can be used to handle even fluids that deposit gummy
residue. A check valve may also utilize a plunger, which is spring-loaded and
usually used to prevent backflow of pressurized gases, or backpressure. A
pop pet in a check valve is spring-loaded and typically installed in systems
that require prevention of backpressure.
Because check valves have so many applications, they are made of a wide
variety of materials. Some companies exclusively manufacture plastic check
valves. Other companies produce check valves made of brass, electro less
nickel plated brass and stainless steel. The components of valves may be
made of different materials, such as cast iron or bronze, depending on the
application. Specialized valves may also be constructed of Teflon. Elastomer
products may also be used to construct valves.
What are Gate Valves?
A Gate Valve, or Sluice Valve, as it is sometimes known, is a valve that opens
by lifting a round or rectangular gate/wedge out of the path of the fluid. The
distinct feature of a gate valve is the sealing surfaces between the gate and
seats are planar. The gate faces can form a wedge shape or they can be
parallel. Gate valves are sometimes used for regulating flow, but many are not
suited for that purpose, having been designed to be fully opened or closed.
When fully open, the typical gate valve has no obstruction in the flow path,
resulting in very low friction-loss.Gate valves are characterized as having
either a rising or a no rising stem. Rising stems provide a visual indication of
valve position. No rising stems are used where vertical space is limited or
underground.

Fig 10.4: Gate valves
Bonnets provide leak proof closure for the valve body. Gate valves may have
a screw-in, union, or bolted bonnet. Screw-in bonnet is the simplest, offering a
durable, pressure-tight seal. Union bonnet is suitable for applications requiring
frequent inspection and cleaning. It also gives the body added strength.
Bolted bonnet is used for larger valves and higher-pressure applications.
Another type of bonnet construction in a gate valve is pressure seal bonnet.
This construction is adopted for valves for high-pressure service, typically in
excess of 15 MPa (2250 psi). The unique feature about the pressure seal
bonnet is that the body - bonnet joints seals improves as the internal pressure
in the valve increases, compared to other constructions where the increase in
internal pressure tends to create leaks in the body-bonnet joint.
Gate valves normally have flanged ends, which are drilled according to
pipeline compatible flange dimensional standards. Cast Iron, Cast Carbon
Steel, Gun Metal, Stainless Steel, Alloy Steels & Forged Steels are different
materials in which Gate Valves are made available.
What are Globe Valves?
Globe valves are named for their spherical body shape. The two halves of the
valve body are separated by an internal baffle, which has an opening forming
a seat onto which a movable disc can be screwed in to close (or shut) the
valve. In globe valves, the disc is connected to a stem, which is operated by
screw action. When a globe valve is manually operated, a hand wheel turns
the stem. Although globe valves in the past had the spherical bodies, which
gave them their name, many modern globe valves do not have much of a
spherical shape, but the term globe valve is still often used for valves that
have such an internal mechanism. In plumbing, valves with such a
mechanism are also often called stop valves since they don't have the global
appearance, but the term stop valve may refer to valves, which are used to
stop flow even when they have other mechanisms or designs.Globe valves
are used for applications requiring throttling and frequent operation. For
example, globe valves or valves with a similar mechanism may be used as
sampling valves, which are normally shut except when liquid samples are
being taken. Since the baffle restricts flow, they're not recommended where
full, unobstructed flow is required.
Globe valves are typically two-port valves. Ports are openings in the body for
fluid flowing in or out. The two ports may be oriented straight' across from
each other on the body, or oriented at an angle such as a 90 angle. Globe
valves with ports at such an angle are called angle globe valves. A bonnet
provides leak proof closure for the valve body. The threaded section of stem
goes through a hole with matching threads in the bonnet. Globe valves may
have a screw-in, union, or bolted bonnet. Screw-in bonnet is the simplest
bonnet, offering a durable, pressure-tight seal. Union bonnet is suitable for
applications requiring frequent inspection or cleaning. It also gives the body
added strength. A bonnet attached with bolts is used for larger or higherpressure applications. Economical globe valves or stop valves with a similar
mechanism used in plumbing often have a rubber washer at the bottom of the
disc for the seating surface, so that rubber can be compressed against the

seat to form a leak-tight seal when shut.Many globe valves have a class rating
that corresponds to the pressure specifications of ANSI 16.34. Bibcocks and
sillcocks are variations of globe or stop valves used in plumbing. Needle
valves are variations of globe valves where instead of a separate attached
disc piece, the internal end of the stem is conically tapered to act as the disc
to fit into a matching seat for fine flow adjustment. Other different types of
valve usually are called globe style valves because of the shape of the body
or the way of closure of the disk. As an example typical swing check valves
could be called globe type.
Fig 10.5: Globe valves

The above classification is based on functions. The valves could also be
classified based on the type of construction; valves manufactures offer
endless varieties of constructions. Based on operation valves can be broadly
classified as operated valves and self operated valves. Mainly the check
valves are self-operated and all the other types come under operated valve.
The valves can further be classified based on end connections. End
connections mean the arrangement of the attachment of the valves to the
equipment or to the piping. The types of end connections are:
Screwed ends
Socket weld ends
Flanged ends
Butt weld ends
socketed ends
Wafer type ends

The valves can also be classified based on materials of construction. There
can be any number of combinations possible with the materials of
constructions. It is for the piping engineer to select the same in consultation
with the process engineer to suit the process fluid. The environment in which
the valves are installed is also to be considered for selection of materials of
construction. However the most commonly available materials are:
Cast iron
Ductile iron
Bronze
Gun metal
Carbon steel
Stainless steel
Alloy steel
Special alloys
10.1 CONTROL VALVE SELECTION

Control valves handle all kinds of fluids at temperatures from the cryogenic
range to well over 1000F (538C). Selection of a control valve body assembly
requires particular consideration to provide the best available combination of
valve body style, material, and trim construction design for the intended
service. Capacity requirements and system operating pressure ranges also
must be considered in selecting a control valve to ensure satisfactory
operation without undue initial expense. Reputable control valve
manufacturers and their representatives are dedicated to helping select the
control valve most appropriate for the existing service conditions. Because
there are frequently several possible correct choices for an application, it is
important that all the following information be provided:
Type of fluid to be controlled
Temperature of fluid
Viscosity of fluid
Specific gravity of fluid
Flow capacity required (maximum and minimum)
Inlet pressure at valve (maximum and minimum)
Outlet pressure (maximum and minimum)
Pressure drop during normal flowing conditions
Pressure drop at shutoff
Maximum permissible noise level, if pertinent, and the measurement
reference point
Degrees of superheat or existence of flashing, if known
Inlet and outlet pipeline size and schedule
Special tagging information required
Body Material (ASTM A216 grade WCC, ASTM A217 grade WC9,
ASTM A351 CF8M, etc.)
End connections and valve rating (screwed, Class 600 RF flanged,
Class 1500 RTJ flanges, etc.)
Action desired on air failure (valve to open, close, or retain last
controlled position)
Instrument air supply available
Instrument signal (3 to 15 psig, 4 to 20 mA, Hart, etc.)

In addition the following information will require the agreement of the user and
the manufacturer depending on the purchasing and engineering practices
being followed.
Valve type number
Valve size
Valve body construction (angle, double-port, butterfly, etc.)
Valve plug guiding (cage-style, port-guided, etc.)
Valve plug action (push-down-to-close or push-down-to open)
Port size (full or restricted)
Valve trim materials required
Flow action (flow tends to open valve or flow tends to close valve)
Actuator size required
Bonnet style (plain, extension, bellows seal, etc.)
Packing material (PTFE V-ring, laminated graphite, environmental
sealing systems, etc.)
Accessories required (positioner, hand wheel, etc.)
10.1.1 VALVE SELECTION PROCESS
1.0 DETERMINE SERVICE CONDITIONS
(P1, P, Q, T1, Fluid Properties, Allowable Noise, etc).
Select appropriate ANSI Pressure Class required for
valve body and trim.
2.0 CALCULATE PRELIMINARY Cv REQUIRED
Check noise and cavitation levels
3.0 SELECT TRIM TYPE
If no noise or cavitations indication, choose standard trim.
If aerodynamic noise is high, choose Whisper Trim
If liquid noise is high and/or cavitation is indicated, choose
Cavitrol_ III trim.
4.0 SELECT VALVE BODY AND TRIM SIZE
Select valve body and trim size with required Cv.

Note travel; trim group, and shutoff options.
5.0 SELECT TRIM MATERIALS
Select trim materials for your application; make sure trim

selected is available in the trim group for the valve size
selected.
6.0 OPTIONS

Consider options on shutoff, stem packing, etc.
10.1.2 Control Valve Flow Characteristics

The flow characteristic of a control valve is the relationship between the flow
rate through the valve and the valve travel as the travel is varied from 0 to
100%. Inherent flow characteristic refers to the characteristic observed with a
constant pressure drop across the valve. Installed flow characteristic means
the one obtained in service where the pressure drop varies with flow and
other changes in the system.
Characterizing control valves provides for relatively uniform control loop
stability over the expected range of system operating conditions. To establish
the flow characteristic needed to match a given system requires a dynamic
analysis of the control loop. Analyses of the more common processes have
been performed, however, so some useful guidelines for the selection of the
proper flow characteristic can be established. Those guidelines will be
discussed after a brief look at the flow characteristics in use today.
Flow Characteristics
Figure 10.6 illustrates typical flow characteristic curves. The quick-opening
flow characteristic provides for maximum change in flow rate at low valve
travels with a nearly linear relationship. Additional increases in valve travel
give sharply reduced changes in flow rate, and when the valve plug nears the
wide open position, the change in flow rate approaches zero. In a control
valve, the quick opening valve plug is used primarily for on-off service; but it is
also suitable for many applications where a linear valve plug would normally
be specified. The linear flow characteristic curve shows that the flow rate is
directly proportional to the valve travel. This proportional relationship
produces a characteristic with a constant slope so that with constant pressure
drop, the valve gain will be the same at all flows. (Valve gain is the ratio of an
incremental change in valve plug position. Gain is a function of valve size and
configuration, system operating conditions and valve plug characteristic.) The
linear valve plug is commonly specified for liquid level control and for certain
flow control applications requiring constant gain. In the equal-percentage flow
characteristic, equal increments of valve travel produce equal percentage
changes in the existing flow. The change in flow rate is always proportional to
the flow rate just before the change in valve plug, disk, or ball position is
made. When the valve plug, disk, or ball is near its seat, the flow is small; with
a large flow, the change in flow rate will be large. Valves with an equal
percentage flow characteristic are generally used on pressure control
applications and on other applications where a large percentage of the
pressure drop is normally absorbed by the system itself, with only a relatively
small percentage available at the control valve. Valves with an equal
percentage characteristic should also be considered where highly varying
pressure drop conditions can be expected.
10
Fig 10.6: Flow Characteristics

10.1.3 Selection of Flow Characteristic
Some guidelines will help in the selection of the proper flow characteristic.
Remember, however, that there will be occasional exceptions to most of these
guidelines, and that a positive recommendation is possible only by means of a
complete dynamic analysis. Where a linear characteristic is recommended, a
quick opening valve plug could be used, and while the controller will have to
operate on a wider proportional band setting, the same degree of control
accuracy may be expected. The tables below give useful guidelines for
selecting valve characteristics
Table 10.1 Flow Control Process
11
Table 10.2 Liquid Level Systems
10.2 Valve Sizing

Over sizing of valves sometimes occurs when trying to optimize process
performance through a reduction of process variability. This results from using
line-size valves, especially with high-capacity rotary valves, as well as the
conservative addition of multiple safety factors at different stages in the
process design
Over sizing the valve hurts process variability in two ways. First, the
oversized valve puts too much gain in the valve, leaving less flexibility in
adjusting the controller. Best performance results when most loop gain comes
from the controller.
Notice in the gain curve of figure 2-5, the process gain gets quite high in the
region below about 25% valve travel. If the valve is oversized, making it more
likely to operate in or near this region, this high gain can likely mean that the
controller gain will need to be reduced to avoid instability problems with the
loop. This, of course, will mean a penalty of increased process variability.
The second way oversized valves hurt process variability is that an oversized
valve is likely to operate more frequently at lower valve openings where seal
friction can be greater, particularly in rotary valves. Because an oversized
valve produces a disproportionately large flow change for a given increment of
valve travel, this phenomenon can greatly exaggerate the process variability
associated with dead band due to friction.
Regardless of its actual inherent valve characteristic, a severely oversized
valve tends to act more like a quick-Opening valve, which results in high
installed process gain in the lower lift regions (figure 2-5). In addition, when
the valve is oversized, the valve tends to reach system capacity at relatively
low travel, making the flow curve flatten out at higher valve travels (figure 2-5).
For valve travels above about 50 degrees, this valve has become totally
12

ineffective for control purposes because the process gain is approaching zero
and the valve must undergo wide changes in travel with very little resulting
changes in flow. Consequently, there is little hope of achieving acceptable
process variability in this region.
Fig 10.7 Installed flow characteristics and gain

The valve shown in figure 2-5 is totally misapplied in this application because it
has such a narrow control range (approximately 25 degrees to 45 degrees).
This situation came about because a line-sized butterfly valve was chosen,
primarily due to its low cost, and no consideration was given to the lost profit
that results from sacrificing process variability through poor dynamic
performance of the control valve.
Unfortunately, this situation is often repeated. Process control studies show
that, for some industries, the majority of valves currently in process control
loops are oversized for the application. While it might seem counterintuitive, it
often makes economic sense to select a control valve for present conditions
and then replace the valve when conditions change.
When selecting a valve, it is important to consider the valve style, inherent
characteristic, and valve size that will provide the broadest possible control
range for the application.
Standardization activities for control valve sizing can be traced back to the
early 1960s when a trade association, the Fluids Control Institute, published
sizing equations for use with both compressible and incompressible fluids.
The range of service conditions that could be accommodated accurately by
these equations was quite narrow, and the standard did not achieve a high
degree of acceptance. In 1967, the ISA established a committee to develop
and publish standard equations. The efforts of this committee culminated in a
valve sizing procedure that has achieved the status of American National
Standard. Later, a committee of the International Electro technical Commission
(IEC) used the ISA works as a basis to formulate international standards for
sizing control valves. (Some information in this introductory material has been
extracted from ANSI/ISA S75.01 standard with the permission of the publisher,
the ISA.) Except for some slight differences in nomenclature and procedures,
the ISA and IEC standards have been harmonized. ANSI/ISA Standard
13

S75.01 is harmonized with IEC Standards 534-2-1 and 534-2-2. (IEC
Publications 534-2, Sections One and Two for incompressible and
compressible fluids, respectively.)
In the following sections, the nomenclature and procedures are explained, and
sample problems are solved to illustrate their use.
10.2.1 Sizing Valves for Liquids
Following is a step-by-step procedure for the sizing of control valves for liquid
flow using the IEC procedure. Each of these steps is important and must be
considered during any valve sizing procedure. Steps 3 and 4 concern the
determination of certain sizing factors that may or may not be required in the
sizing equation depending on the service conditions of the sizing problem. If
one, two, or all three of these sizing factors are to be included in the equation
for a particular sizing problem, refer to the appropriate factor determination
sections) located in the text after the sixth step.
1. Specify the variables required to size the valve as follows:
Desired design: refer to the appropriate valve flow coefficient
table in this chapter.
Process fluid (water, oil, etc.), and
Appropriate service conditions

q or w, P1, P2 or P, T1, Gf, Pv, Pc, and
The ability to recognize which terms are appropriate for a specific sizing
procedure can only be acquired through experience with different valve sizing
problems. If any of the above terms appears to be new or unfamiliar, refer to
the Abbreviations and Terminology table for a complete definition.
2. Determine the equation constant; N. N is a numerical constant contained in
each of the flow equations to provide a means for using different systems of
units. Values for these various constants and their applicable units are given in
the Equation Constants table.
Use N1, if sizing the valve for a flow rate in volumetric units (gpm or m3/h).
Use N6 if sizing the valve for a flow rate in mass units (lb/h or kg/h).
3. Determine Fp, the piping geometry factor.
Fp is a correction factor that accounts for pressure losses due to piping fittings
such as reducers, elbows, or tees that might be attached directly to the inlet
and outlet connections of the control valve to be sized. If such fittings are
attached to the valve, the Fp factor must be considered in the sizing procedure.
If, however, no fittings are attached to the valve, Fp has a value of 1.0 and
simply drops out of the sizing equation.
14
Table 10.3 Abbreviations and Terminologies
For rotary valves with reducers (swaged installations), Fp factors are included
in the appropriate flow coefficient table. For other valve designs and fitting
styles, determine the Fp factors by using the procedure for Determining Fp, the
Piping Geometry Factor.
15
Table 10.4 Equation Constants
4. Determine qmax (the maximum flow rate at given upstream conditions) or

Pmax (the allowable sizing pressure drop).
The maximum or limiting flow rate (qmax), commonly called choked flow, is
manifested by no additional increase in flow rate with increasing pressure
differential with fixed upstream conditions. In liquids, choking occurs as a
result of vaporization of the liquid when the static pressure within the valve
drops below the vapor pressure of the liquid.
The IEC standard requires the calculation of an allowable sizing pressure drop
(Pmax), to account for the possibility of choked flow conditions within the valve.
The calculated Pmax value is compared with the actual pressure drop specified
in the service conditions, and the lesser of these two values is used in the
sizing equation. If it is desired to use Pmax to account for the possibility of
choked flow conditions, it can be calculated using the procedure for
determining qmax, the Maximum Flow Rate, or Pmax, the Allowable Sizing
Pressure Drop. If it can be recognized that choked flow conditions will not
develop within the valve, APmax need not be calculated.
5. Solve for required Cv, using the appropriate equation:
For volumetric flow rate units
16

(10.1)
For mass flow rate
units
(10.2)
In addition to Cv, two other

flow coefficients, Kv and
Av, are used, particularly outside of North America. The following relationships
exist:
Kv = (0.865)(Cv)
Av = (2.40 X 10-5)(Cv)
6. Select the valve size using the appropriate flow coefficient table and the
calculated Cv value.
10.2 2 Determining Fp, the Piping Geometry Factor
Determine an Fp factor if any fittings such as reducers, elbows, or tees will be
directly attached to the inlet and outlet connections of the control valve that is
to be sized. When possible, it is recommended that F p factors be determined
experimentally by using the specified valve in actual tests. The Fp factors for
rotary valves used with reducers have all been determined in this manner, and
their values are listed in the flow coefficient tables.
For Fp values not listed in the flow coefficient tables, calculate the Fp factor
using the following equation.
(10.3)
N2 = Numerical constant found in the Equation Constants table
d = Assumed nominal valve size.
Cv = Valve sizing coefficient at 100-percent travel for the assumed valve size
In the above equation, the K term is the algebraic sum of the velocity head
loss coefficients of all of the fittings that are attached to the control valve.
K = K1 + K2 + KB1 - KB2
Where,
K1 = Resistance coefficient of upstream fittings
K2 = Resistance coefficient of downstream fittings
KB1 = Inlet Bernoulli coefficient
KB2 = Outlet Bernoulli coefficient
The Bernoulli coefficients, KB1 and KB2, are used only when the diameter of the
piping approaching the valve is different from the diameter of the piping leaving
the valve, whereby:
(10.4)
17

Where,
d = Nominal valve size
D = Internal diameter of piping
If the inlet and outlet piping are of equal size, then the Bernoulli coefficients are
also equal, KB1 = KB2, and therefore they are dropped from the equation.
The most commonly used fitting in control valve installations is the short-length
concentric reducer. The equations for this fitting are as follows:
For an inlet reducer
(10.5)
For an outlet reducer

(10.6)
For a valve installed between identical reducers

(10.7)
Determining qmax (the Maximum Flow Rate) or Pmax (the Allowable

Sizing Pressure Drop)
Determine either qmax or Pmax if possible for choked flow to develop within
the control valve that is to be sized. The values can be determined by using
the following procedures.
Determining qmax (the Maximum Flow Rate)
(10.8)
Values for FF, the liquid critical pressure ratio factor, can be obtained from the
following equation:
(10.9)
Values of FL, the recovery factor for valves installed without fittings attached,
can be found in the flow coefficient tables. If the given valve is to be installed
with fittings such as reducer attached to it, F L in the equation must be
replaced by the quotient FLP/Fp, where:
18

(10.10)
And
K1 = K1 + KB1
Where,
K1 = Resistance coefficient of upstream fittings
KB1 = Inlet Bernoulli coefficient
Determining Pmax (the Allowable Sizing Pressure Drop)
Pmax (the allowable sizing pressure drop) can be determined from the
following relationships:
For valves installed without fittings(10.11)
For valves installed with fittings attached(10.12)
Where,
P1 = Upstream absolute static pressure
P2= Downstream absolute static pressure
Pv = Absolute vapor pressure at inlet temperature
Values of FF, the liquid critical pressure ratio factor, can be obtained from
Figure 5-2 or from the following equation:
(10.13)
Values of FL, the
recovery
factor
for
valves installed without fittings attached, can be found in the flow coefficient
tables. An explanation of how to calculate values of F LP, the recovery factor for
valves installed with fittings attached, is presented in the procedure for
determining qmax (the Maximum Flow Rate).
19
Fig 10.8 Liquid critical pressure ratio curve

Once the Pmax value has been obtained from the appropriate equation, it
should be compared with the actual service pressure differential (P = P1 P2). If Pmax is less than P, this is an indication that choked flow conditions
will exist under the service conditions specified. If choked flow conditions do
exist (Pmax < P1 - P2), then step 5 of the procedure for Sizing Valves for
Liquids must be modified by replacing the actual service pressure differential
(P1 - P2) in the appropriate valve sizing equation with the calculated Pmax
value
10.2.3 Liquid Sizing Sample Problem
Assume an installation that, at initial plant start-up, will not be operating at
maximum design capability. The lines are sized for the ultimate system
capacity, but there is a desire to install a control valve now, which is sized only
for currently anticipated requirements. The line size is 8 inches, and a Class
300 globe valve with an equal percentage cage has been specified. Standard
concentric reducers will be used to install the valve into the line.
Determine the appropriate valve size.
1. Specify the necessary variables required to size the valve:
Desired valve designClass 300 globe valve with equal
percentage cage and an assumed valve size of 3 inches.
Process fluidliquid propane
Service conditions
q = 800 gpm
20

P1 = 300 psig = 314.7 psia
P2 = 275 psig = 289.7 psia
P = 25 psi
T1 = 70F
Gf = 0.50
Pv = 124.3 psia
Pc = 616.3 psia
2. Determine an N1 value of 1.0 from the Equation Constants table.
Because it is proposed to install a 3-inch valve in an 8-inch line, it will be
necessary to determine the piping geometry factor, F p, which corrects for
Losses caused by fittings attached to the valve.
(10.14)
Where,
N2 = 890, from the Equation Constants table
d = 3 in., from step 1
Cv = 121, from the flow coefficient table for a Class 300, 3 in. Globe valve with
equal percentage cage
To compute K for a valve installed between identical concentric reducers:
Where,
D = 8 in., the internal diameter of the piping so,
4. Determine Pmax (the Allowable Sizing Pressure Drop.)
21

Based on the small-required pressure drop, the flow will not be choked (Pmax
> P).
5. Solve for Cv, using the appropriate equation.
6. Select the valve size using the flow coefficient table and the calculated C v
value. The required Cv of 125.7 exceeds the capacity of the assumed valve,
which has a Cv of 121. Although for this example it may be obvious that the
next larger size (4 inches) would be the correct valve size, this may not
always be true, and a repeat of the above procedure should be carried out.
Assuming a 4-inch valve, Cv = 203. This value was determined from the flow
coefficient table for a Class 300, 4-inch globe valve with an equal percentage
cage.
Recalculate the required Cv using an assumed Cv value of 203 in the Fp
calculation.
where,
22
=121.7
This solution indicates only that the 4-inch valve is large enough to satisfy the
service conditions given. There may be cases, however, where a more
accurate prediction of the Cv is required. In such cases, the required C v should
be redetermined using a new F p value based on the Cv value obtained above.
In this example, Cv is 121.7, which leads to the following result:
The required Cv then becomes:
23

Because this newly determined Cv is very close to the Cv used initially for this
recalculation (116.2 versus 121.7), the valve sizing procedure is complete,
and the conclusion is that a 4-inch valve opened to about 75-percent of total
travel should be adequate for the required specifications.
10.3 Sizing Valves for Compressible Fluids
Following is a six-step procedure for the sizing of control valves for
compressible flow using the ISA standardized procedure. Each of these steps
is important and must be considered during any valve sizing procedure. Steps
3 and 4 concern the determination of certain sizing factors that may or may
not be required in the sizing equation depending on the service conditions of
the sizing problem. If it is necessary for one or both of these sizing factors to
be included in the sizing equation for a particular sizing problem, refer to the
appropriate factor determination section(s), which is referenced and located in
the following text.
1. Specify the necessary variables required to size the valve as follows:
Desired valve design (e.g. balanced globe with linear cage); refer to
the appropriate valve flow coefficient table
Process fluid (air, natural gas, steam, etc.) and
Appropriate service conditions
q, or w, P1, P2 or P, T1, Gg, M, k, Z, and 1
The ability to recognize which terms are appropriate for a specific sizing
procedure can only be acquired through experience with different valve sizing
problems. If any of the above terms appear to be new or unfamiliar, refer to
the Abbreviations and Terminology table for a complete definition.
2. Determine the equation constant; N. N is a numerical constant contained in
each of the flow equations to provide a means for using different systems of
units. Values for these various constants and their applicable units are given
in the Equation Constants table.
Use either N7 or N9 if sizing the valve for a flow rate in volumetric units (scfh or
m3/h). Which of the two constants to use depends upon the specified service
conditions. N7 can be used only if the specific gravity, Gg, of the following gas
has been specified along with the other required service conditions. N 9 can be
used only if the molecular weight, M, of the gas has been specified.
Use either N6 or N8 if sizing the valve for a flow rate in mass units (lb/h or
kg/h). Which of the two constants to use depends upon the specified service
conditions. N6 can be used only if the specific weight, 1, of the flowing gas
has been specified along with the other required service conditions. N 8 can be
used only if the molecular weight, M, of the gas has been specified.
3. Determine Fp, the piping geometry factor. F p is a correction factor that
accounts for any pressure losses due to piping fittings such as reducers,
elbows, or tees that might be attached directly to the inlet and outlet
24

connections of the control valves to be sized. If such fittings are attached to
the valve, the Fp factor must be considered in the sizing procedure. If,
however, no fittings are attached to the valve, F p has a value of 1.0 and simply
drops out of the sizing equation.
Also, for rotary valves with reducers, F p factors are included in the appropriate
flow coefficient table. For other valve designs and fitting styles, determine the
Fp factors by using the procedure for Determining F p the Piping Geometry
Factor, which is located in the section for Sizing Valves for Liquids.
4. Determine Y, the expansion factor, as follows:
(10.15)
Where,
Fk = k/1.4, the ratio of specific heats factor
k = Ratio of specific heats
x = P/P1, the pressure drop ratio
xT = The pressure drop ratio factor for valves installed without attached
fittings. More definitively, xT is the pressure drop ratio required to produce
critical, or maximum, flow through the valve when Fk = 1.0
If the control valve to be installed has fittings such as reducers or elbows
attached to it, then their effect is accounted for in the expansion factor
equation by replacing the xT term with a new factor xTP. A procedure for
determining the xTP factor is described in the section for Determining x TP, the
Pressure Drop Ratio Factor.
Note
Conditions of critical pressure drop are realized when the value of x
becomes equal to or exceeds the appropriate value of the product of
either Fk xT or Fk xTP at which point:
Although in actual service, pressure drop ratios can, and often will, exceed the
indicated critical values, this is the point where critical flow conditions develop.
Thus, for a constant P 1, decreasing P2 (i.e., increasing P) will not result in an
increase in the flow rate through the valve. Values of x, therefore, greater than
the product of either FkxT or FkxTP must never be substituted in the expression
for Y. This means that Y can never be less than 0.667. This same limit on
values of x also applies to the flow equations that are introduced in the next
section.
5. Solve for the required Cv using the appropriate equation:
For volumetric flow rate units
25

If the specific gravity, Gg, of the gas has been specified:
(10.16)
If the molecular weight, M, of the gas has been specified:
(10.17)
For mass flow rate units

If the specific weight, 1, of the gas has been specified:
(10.18)
If the molecular weight, M, of the gas has been specified:

(10.19)
In addition to Cv, two other flow coefficients, K v and Av, are used, particularly
outside of North America. The following relationships exist:
Kv = (0.865)(Cv)
Av =2.40 X 10 -5(Cv)
Note
Once the valve sizing procedure is completed, consideration can be
made for aerodynamic noise prediction. To determine the gas flow sizing
coefficient (Cg) for use in the aerodynamic noise prediction technique, use the following equation:
(10.20)
Determining xTP, the Pressure Drop Ratio Factor
If the control valve is to be installed with attached fittings such as reducers or
elbows, then their effect is accounted for in the expansion factor equation by
replacing the xT term with a new factor, xTP.
26

(10.21)
Where,
N5 = Numerical constant found in the Equation Constants table
d = Assumed nominal valve size
Cv = Valve sizing coefficient from flow coefficient table at 100 percent travel for
the assumed valve size
Fp = Piping geometry factor
xT = Pressure drop ratio for valves installed without fittings attached. xT values
are included in the flow coefficient tables
In the above equation, Ki, is the inlet head loss coefficient, which is defined
as:
Ki = K1+KB1
Where,
K1 = Resistance coefficient of upstream fittings (see the procedure for
Determining Fp, the Piping Geometry Factor, which is contained in the section
for Sizing Valves for Liquids).
KB1 = Inlet Bernoulli coefficient (see the procedure for Determining F p, the
piping Geometry factor, which is contained in the section for Sizing Valves for
Liquids.)
Compressible Fluid Sizing
Sample Problem No. 1
Determine the size and percent opening for a Fisher Design V250 ball valve
operating with the following service conditions. Assume that the valve and line
size are equal.
Desired valve designDesign V250 valve
Process fluidNatural gas
Service conditions
P1 = 200 psig = 214.7 psia
P2 = 50 psig = 64.7 psia
P = 150 psi
x = P/P1 = 150/214.7 = 0.70
T1 = 60F = 520R
M = 17.38
Gg = 0.60
k = 1.31
q = 6.0 x 106 scfh
2. Determine the appropriate equation constant, N, from the Equation
Constants table.
27

Because both Gg and M have been given in the service conditions, it is
possible to use an equation containing either N7 or N9. In either case, the end
result will be the same. Assume that the equation containing G g has been
arbitrarily selected for this problem. Therefore N7 = 1360.
3. Determine Fp, the piping geometry factor. Since valve and line size are
assumed equal, Fp = 1.0.
4. Determine Y, the expansion factor.
It is assumed that an 8-inch Design V250 valve will be adequate for the
specified service conditions. From the flow coefficient table, xT for an 8-inch
Design V250 valve at 100-percent travel is 0.137.
x = 0.70 (This was calculated in step 1.)
Since conditions of critical pressure drop are realized when the calculated
value of x becomes equal to or exceeds the appropriate value of F kxT, these
values should be compared.
FkxT =(0.94) (0.137)
= 0.129
Because the pressure drop ratio, x = 0.70 exceeds the calculated critical
value, FkxT = 0.129, choked flow conditions are indicated. Therefore, Y =
0.667, and x = FKXT = 0.129.
5. Solve for required Cv using the appropriate equation.
The
compressibility
factor, Z, can be
assumed to be 1.0 for the gas pressure and temperature given and F p = 1
because valve size and line size are equal.
So,
The above result indicates that the valve is adequately sized (rated C v =
2190). To determine the percent valve opening, note that the required C v
28

occurs at approximately 83 degrees for the 8-inch Design V250 valve. Note
also that, at 83 degrees opening, the x T value is 0.252, which is substantially
different from the rated value of 0.137 used initially in the problem. The next
step is to rework the problem using the xT value for 83 degrees travel.
The Fk xT product must now be recalculated.
x = Fk xT
= (0.94) (0.252)
= 0.237
The required Cv now becomes:
The reason that the required C v has dropped so dramatically is attributable

solely to the difference in the x T values at rated and 83 degrees travel. A C v of
1118 occurs between 75 and 80 degrees travel.
The appropriate flow coefficient table indicates that x T is higher at 75 degrees
travel than at 80 degrees travel. Therefore, if the problem were to be
reworked using a higher xT value, this should result in a further decline in the
calculated required Cv.
Reworking the problem using the x T value corresponding to 78 degrees travel
(i.e., xT = 0.328) leaves:
x = Fk xT
= (0.94) (0.328)
= 0.308
and,
29

The above Cv of 980 is quite close to the 75 degree travel C v. The problem
could be reworked further to obtain a more precise predicted opening;
however, for the service conditions given, an 8-inch Design V250 valve
installed in an 8-inch line will be approximately 75 degrees open.
Compressible Fluid Sizing
Sample Problem No. 2
Assume steam is to be supplied to a process designed to operate at 250 psig.
The supply source is a header maintained at 500 psig and 500_F. A 6-inch
line from the steam main to the process is being planned. Also, make the
assumption that if the required valve size is less than 6 inches, it will be
installed using concentric reducers. Determine the appropriate Design ED
valve with a linear cage.
a. Desired valve designClass 300 Design ED valve with a linear
cage. Assume valve size is 4 inches.
b. Process fluidsuperheated steam
c. Service conditions
w = 125,000 lb/h
P1 = 500 psig = 514.7 psia
P2 = 250 psig = 264.7 psia
P = 250 psi
x = P/P1 = 250/514.7 = 0.49
T1 = 500F
1 = 1.0434 lb/ft3 (from Properties of Saturated Steam table)
k= 1.28 (from Properties of Saturated Steam table)
2. Determine the appropriate equation constant, N, from the Equation
Constants table.
Because the specified flow rate is in mass units, (lb/h), and the specific weight
of the steam is also specified, the only sizing equation that can be used is that
which contains the N6 constant. Therefore, N6= 63.3
Where,
N2 = 890, determined from the Equation Constants table
d = 4 in.
Cv = 236, which is the value listed in the manufacturers Flow Coefficient table
for a 4-inch Design ED valve at 100-percent total travel.
and
30
Finally:
4. Determine Y, the expansion factor,
where,
x = 0.49 (As calculated in step 1.)

Because the 4-inch valve is to be installed in a 6-inch line, the xT term must
be replaced by xTP.
Where,
N5 = 1000, from the Equation Constants table
d = 4 in.
Fp = 0.95, determined in step 3
xT = 0.688, a value determined from the appropriate listing in the
manufacturers Flow Coefficient table
Cv = 236, from step 3
and
Ki= K1+KB1
Where
D = 6 in.
31

So:
Finally:
5. Solve for required Cv using the appropriate equation.
6. Select the valve size using the appropriate manufacturers Flow Coefficient
table and the calculated Cv value.
Refer to the manufacturers Flow Coefficient tables for Design ED valves with
linear cage. Because the assumed 4-inch valve has a C v of 236 at 100percent travel and the next smaller size (3 inches) has a C v of only 148, it can
be surmised that the assumed size is correct. In the event that the calculated
required Cv had been small enough to be handled by the next smaller size or
if it had been larger than the rated C v for the assumed size, it would have
been necessary to rework the problem again using values for the new
assumed size.
32

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Rolta Academy:Engineering Design Services

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Fig 10.2: Butterfly valve

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Rolta Academy:Engineering Design Services

Rolta Academy:Engineering Design Services

Fig 10.5: Globe valves

Socket weld ends

Butt weld ends

Wafer type ends

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10.1 CONTROL VALVE SELECTION

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Select valve body and trim size with required Cv.

5.0 SELECT TRIM MATERIALS

Select trim materials for your application; make sure trim

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10.1.2 Control Valve Flow Characteristics

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Fig 10.6: Flow Characteristics

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Table 10.2 Liquid Level Systems

10.2 Valve Sizing

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Fig 10.7 Installed flow characteristics and gain

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Process fluid (water, oil, etc.), and

Appropriate service conditions

Rolta Academy:Engineering Design Services

Table 10.3 Abbreviations and Terminologies

Rolta Academy:Engineering Design Services

Table 10.4 Equation Constants

4. Determine qmax (the maximum flow rate at given upstream conditions) or

Rolta Academy:Engineering Design Services

For mass flow rate

In addition to Cv, two other

Rolta Academy:Engineering Design Services

For an outlet reducer

For a valve installed between identical reducers

Determining qmax (the Maximum Flow Rate) or Pmax (the Allowable

Rolta Academy:Engineering Design Services

Rolta Academy:Engineering Design Services

Fig 10.8 Liquid critical pressure ratio curve

Rolta Academy:Engineering Design Services

4. Determine Pmax (the Allowable Sizing Pressure Drop.)

Rolta Academy:Engineering Design Services

Rolta Academy:Engineering Design Services

Rolta Academy:Engineering Design Services

Rolta Academy:Engineering Design Services

Rolta Academy:Engineering Design Services

If the molecular weight, M, of the gas has been specified:

For mass flow rate units

If the molecular weight, M, of the gas has been specified:

Rolta Academy:Engineering Design Services

Rolta Academy:Engineering Design Services

Rolta Academy:Engineering Design Services

The reason that the required C v has dropped so dramatically is attributable

Rolta Academy:Engineering Design Services

Rolta Academy:Engineering Design Services

4. Determine Y, the expansion factor,

x = 0.49 (As calculated in step 1.)