FEATURE REPORT Part 1 AVOID PITFALLS WHEN SPECIFYING CONTROL VALVES idespread availability of valvesizing software has made customere? purchasing of modulat- jing control valves de- ceptively easy. However, the sizing cal- culations are not the whole story when, specifying the valve — it is also neces- sary to take into account a variety of practical considerations Accordingly, ‘keep the following guidelines in mind, whenever selecting control valves: 1. Anticipate possible variations in process conditions Avalve's flow coefficient (C,; box, p. 77) rust be chosen so as to allow the valve to perform at the intended flowrates even if unexpected changes in the process conditions arise, Take particu- Jar care to anticipate any possible shifts in the temperature and the upstream and downstream pressure of the flow- ing fluid ‘The directions of such changes (in- crease or decrease) may not always be consistent. They may or may not be time-dependent. And as the example in Figure 1 brings out, they may well vary according to how widely the valve is open. In any case, the best way to an- ticipate changes is to develop a full un- derstanding of the process system within which the valve is to perform, 2. Take into account the overall Process setting Similarly, future operating problems are likely to arise if the engineer spec- ifying the control valve is not provided With @ deseription of ‘the physical set- ting in which the valve is to perform, Before trying to specify the valve, insist R.Michael Bell Stone & Webster Engineering Corp. oa 175: ‘800, c a 3 Ve | in wt 3 a — 20 40 60 80 100 Percent of maximum flow FIGURE 1. Oftn overiookedis theimpact thatthe extent ofthe valve opening can’ Itsefhave upon the process varllables Consider process layout, fluid properties, the risk of cavitation, anda variety of other factors ‘on being given the line sizes, pump flowrates, elevations and pressure drops of individual pieces of equipment in the process unit, and similar data. Armed with that information, adhere to these guidelines and good practices: ‘a. At full flow, the pressure drop across the valve should be at least 50% of the friction pressure drop across the rest of the system (ie., excluding the valve) In typical systems, tis fretion drop is about one-third ofthe total ays- tem drop For example, consider a process set- ting with these conditions: Ap due to elevation: 15 Ap across process equipment: 90 psi Ap due to system friction: 85 psi ‘Ap across valve at max. flow: 20 psi ‘Total Ap for system: 100 psi In this example, 50% ofthe 3-psi ric tion pressure drop is 1.5 psi 6 the 20 pei allocated to the valve is acceptable. }, Atfl lw, the pressure drop across the valve should be at least 39% ofthe total pressure drop (due to friction, ele- vation, and process equipment) across the rest of the system (excluding the valve) [1, 6,8). If that guideline cannot be met, here are the minimum condi- tions upon which to insist: * With equal-percentage-rim valves: 10% of aystem pressure drop [4,8] * With linear-trim valves: 25% of sys- tem pressure drop [4 51 * With pumped systems: 15 psi (6, 8] In all cases, tho more pressure drup that is allocated to the valve, the better is the control. Tn the above example, 80% of the total system drop is other than across the valve, The recommended pressure drop allocated to the valve would be: 3% x BOS, or 26% of the total system drop, Because only 20 psi (20%) was al located, use equal-percentage. trim. (Gee also Point fin this section . Specify a Cy large enovgh s0 that the maximum ‘processlow require- ment will be equivalent to no more than 80-90% ofthat C,. This guideline provides for modulating overshoot [6 4. Conversely, the minimum pro CHEMICAL ENGINEERING /OECEMBER 1906 75FEATURE REPORT in. Flow eet pressure ‘Thetformatof ‘TABLE 2, ‘atright, Ispreterable ‘because itis not ambiguous Inlet pressure Outlet pressure ‘Temperatu flow should require a C, greater than 10% ofthe C, of the valve selected. This js essential with wet steam to avoid damage to valve trim [6] To forestall materials problems, select valves large enough so that the maximum liquid inlet velocities are as follows (7: ‘cast-iron valve body: 18 fUs carbon-steel valve body: 25 fs Type 316 stainless-stee! valve body: 85 fus '£ Bqual-perventage trim is more for giving if valve sizing proves to be incor- rect, if process conditions change, or if insufficient pressure drop is allocated to the valve. ig. The valve inlet and outlet can be the same size (diameter) as the pipe line, or one size or two sizes smaller, but jn no case less than 50% of the line size. 3. Insist on data that relate the process conditions properly ‘The customary formatting of tabulated data often implies a relationship be- ‘ween temperature, pressure, and flow that is incorrect, Such tabulation should always be questioned or, prefer= ably, avoided. Tn particular, valve sizing informa tion is often tabulated as in Table 1. ‘This tabulation leads to a common mistake: calculating the maximum , using the maximum flow, temper ature, inlet pressure, and outlet pres- sure. In practice, maximum tempera ture and pressure rarely occur simultaneously with maximum flow. Similar problems occur with sizing “The conventional data format shown In TABLE 4, lf, can mislead ‘Atnormal ‘To avoid such confusion, request that the data be tabulated as shown in ‘Table 2. This approach provides an added benefit — it eliminates the risk ‘of confusing the vessel or pipeline rat ing with the maximum process operat- ing pressure. 4, Keep in mind how the process variables govern the required size for the valve For valves that handle gases, the gen eralized valve-sizing relationship is Co ~ QIGTIP; — PakP; + Pp) where @ is the maximum volumetric Pressure along flow ‘in maigo valve CAVITATION Pressure of : flowing iguld 3 FLASHING Liguld vapor 8 pressure. g wommat y \ 2 2 ||_/___l Liquid vapor pressure A A iS Flow Vena Flow entors contracta exis ave “oceurs. valve ‘body near valve plug Rowrate, G is the specific gravity, Tis the absolute temperature, and Py and Pp are the inlet and outlet, absolute pressures, respectively.” 'As this expression brings oul, the re- quired C, varies directly with flowrate fand with the square roots of specific gravity and temperature, and inversely ‘with the square root of system pressure (as represented by [PL + P2), and dif: ferential pressure With liquids, the generalized valve- sizing relationship is 6, ~ QGIPs ~ Pe)M ‘Ths, for control valves that handle lig- uids, the required Cy varies directly ‘with the flowrate and with the square Toot of the specific gravity, and in- versely with the square root of the dif ferential pressure. "This relationship is simpler than the cone for gas flow. However, specifying @ Walve for liquid flow entails a serious FIGURE 2 , Presence of cavitation, tosh ing or normal valve operalion(respec™ tively, top te bottom graphs ) depends on tho relative values ofthe lowing fiquid's factual pressure and vapor pressure possibilities of cavitation or flashing within the valve ‘5. Take account of any potential for cavitation and flashing Bach of these problems occur because the fluid pressure inside the valve drops below the fluid vapor pressure. Cavitation (upper graph, Figure 2) prevails only at the vena contracts fand immediately downstream, the fluid “collapsing” back into liquid as it continues downstream. With flashing (niddle graph, Figure 2), the fluid re- mains a vapor after leaving the valve. Both situations are at odds with the various more-complex versions of this exes Yartouy gern ia logs for gull ow, son an ot San valve vendors well ae for normal and minimum flow. 76 risk that does not arise with gases: the CHEMICAL ENGINEERING / DECEMBER 1096 axe ey Se fr Mearurtbent and Co esaRen, [|| {fF is D 5 i 20% OPEN. por ] Normat |}| @ é E how | pressure Flow Vena Flow entorscontracta exits valve body valve LU ACONTROL-VALVE GLOSSARY Cv: a low coefficient, italy defined as the numberof the U.S. gallons-per-minute of ‘ator that wil pass through a low restriction under a pressure drop of 1 psi. Sinca Is Introduction by Masonellan In 1944, Cv has also been adapted for use in sizing valves for gases and steam a Cavitation: a condition in which a liquid vaporizes into bubbles near the plug and seat of valve, or other pipeline flow obstruction, then collapses back toa quid as pros: ‘sure recovers (Increases) downstream ofthe valve (see also Vena contacta) Equal percentage trim: a valve trim witha flow response that is nonlinear under pre- ferred process conditions (those recommended in this atc), so that a plot of the flowrate vs. te it ofthe plug is a curve. When conditions are not thus, the plot ofthe ‘actual response tends to become a straight ine. Accordingly, the valve retains good ‘conta from 20% to 90% ofthe valve opening Flashing: a condition similar to cavitation, except that the dovmstream pressure and ‘temperature are such thatthe process fd remains a vapor downstream of the valve, Linear trim: a valve trim wit a flow response that is near under preferred conditions —a plot of flowrate vs. the lit ofthe plug is a straight line. If conditions are not thus, ‘the plot ofthe actual response is no longer linear and poor coro wil resuit at 70% to 100% of valve opening Pressure recovery: an increase in system pressure, due to change from kinetic to pressure energy downstream ofthe vena contracta Valve-ecovery coefficient: a numerical factor that represents a valve'sflow-vs.- pressure curve and thus the valve's tendency to cavitate, Typical values range from 0,600.99. A value 0.6 is a high recovery factor, indicating a deep pressure dip and a higher possibilty of cavitation than with a factor nearer to 0.98. Most globe valves have a recovery factor of 0.9 ‘Vena contracta: the point na valve where the fui flow reaches a maximum fuld ve- locty and minimum fui pressure. The vena contracta occurs just downstream of the ‘low obstruction posed by the valve plug FIGURE 9. The extent of valve opening (shown here for 15% open and 80% open) tan not ony affect process properties, 2 Shown in Figure 1, butalso mean thecifer- fence between cavitation and normal ow desired flow-vs-pressure profile through the valve (lower graph, Fig- ure 2), and thus limit the effectiveness, of the valve. Cavitation or flashing occur because pressure energy in the fluid converts to kinetic energy as the contraction in the valve causes an increase in velocity (Some energy in the stream is also di sipated as friction and heating, as well as noise, For information related to the or flashing | noise problems with gascous ‘low through a valvo, so pp. 7881.) As the ‘potential | temperature of the liquid increases, e cavitation and flashing become more ur beeause | likely, du to inereased vapor pressure. the valve Cavitation and flashing greatly in- + pressure, | ereaso the Cy requirement, often to the Figure 2) | Point where no additional flow is possi contracta | ble even with additional differential eam, the | PTeasure across the valve. This condi- quid as it | tion isknown as choked flow. h flashing Cavitation can also damage the valve e fluid re- | and piping. The damage is due to local- the valve, | ized mechanical forces (upto 5,000 psi), swith the | hich can rapidly erode metal surfaces. ‘The extent of cavitation depends mainly on the downstream pressure ‘and the differential pressure across the valve. Cavitation is not normally dam- aging at inlet pressures under 50 psig. | References ‘The higher the downstream pressure or |. "Masizelan Taya Coto Vs Si the lower the diferental pressure, the ea cout ee Jess likely is the valve to cavitate. ‘Noise Control Manual," Bulletin The valve itself changes these last- oh TS named two conditions, as its plug pos- |, vingsJr, Oternning And Using The Con tion ary through te ange of opening |" Segoe as Yo rt (10% to 90% open) while the valve modi- | «, Dorr, eney W, Flow Churatraos For fies the lw rate in the system, Aocord- | Gg Vale teas, 3H J, Oxober ingly, cavitation doesnot always Ger |g. eh Gil Vt: nae through the fall ange of valve opening | ° How” cil, recanted fe ft igure 9) ‘Tothniog“Ingorty 191Anabem, Cal Flashing is usually due to conditions | 6. Mo, Ralph W, Allocation of Conta Yaive downstream from the valve, so itis dif. | SSPE. wapulsot pepe pronde by ficult to generalize about strategies for | 7 Demi alse! Version 20 Compania Vag preventing it. The engineer can more- | Sa ragam Mano lero ration ae Onan Sea 1 rity ara, inh | here er of one or more ofthe fllowing actions; | ” Aerua Conta! Va Lay Mum 1. Specify a valve with lower recov- | futuflrfnameatatiy fr te cei: cry coefficient than would otherwise be | usin Denk of Chemical Engraecing Texas needed, or use anti-cavitation valve fale te (ln auch ei, th ald undergoes several small pressure drops rather Author iia scale ‘han one large drop.) a eteheies 2 Inercese the, dawmtream_ prs eee Ga deny ereligspaceg tate resets Oe eae Steam ne pine han wala | ME Se er se esc e experts moving the valet Seer 1 lower elevation; or installing a flow Destine a, eee es reetitrdawntroan Se 3. Decrease the liquid temperature | ier th teri Soe snot 4, Decrease the upstream pressure | S Canin ish) wna has edorod ey 10 however, this option usually brings | fer guia gril, Hae Brae about only a minimal improvement) m | fa Few arin Ch My 0 aie 8 ‘Edited by Nicholas P. Chopey | feat o'Sah Fide CHEMICAL ENGINEERING DECEMBER 1996 77