1|A u t h o r e t . a l .

, I C E R I E 2 0 1 3

Proceedings of the
International Conference on Engineering Research, Innovation and Education 2013
ICERIE 2013, 11 ̶ 13 January, SUST, Sylhet, Bangladesh

Sizing and Selection of Control Valve for Process Control Loop

P. K. Bhowmik1,*, P. Dutta2, M. Dey3 and S. K. Dhar4

1
Department of Instrumentation &Communication, Eastern Refinery Ltd., Chittagong, Bangladesh
2
Department of, Energy Auditing Unit-2, Bangladesh Power Development Board, Chittagong
3
Department of EEE, Chittagong University of Engineering & Technology, Bangladesh
4
Member Institute of Electrical & Electronic Engineers, Chittagong, Bangladesh

Keywords: Abstract: The purpose of this paper is to provide an understanding of the key issues
Process control, involved in the sizing and selection of control valve for typical process control
applications. Control valve is the most common final control element of process
Control valve, Sizing
control loop. It manipulates a flowing fluid to compensate for the load disturbance and
and Selection, Sizing keep the regulated process variable as close as possible to the desired set point. So
proper sizing, selection, manufacture, test, installation and maintenance of control
equations, Factors for
valve are all significant to obtain precise control performances. This paper proposes
sizing and selection better flexibility for sizing and selection of appropriate control valve and it’s
accessories to ensure the best control performance and safety of process control loop in
a cost effective way.

1. INTRODUCTION

Control valves are the essential final elements used to control fluid flow and pressure conditions in a vast range of
industrial processes. It provides the means of implementing or actuating of a control strategy for a given process
application. Control valves are normally regarded as valves that provide a continuously variable flow area for the
purpose of regulating or adjusting the steady state running conditions of a process. The influence of control valves
on the performance of high value processes worldwide is very much larger. Hence control and instrumentation
engineers have to deliver the best possible control valve choices for every application they encounter [1].
The task of specifying and selecting the appropriate control valve for any given application requires an
understanding of the principles of: how fluid flow and pressure conditions determine what happens inside a control
valve, how control valves act to modify pressure and flow conditions in a process, what types of valves are
commonly available, how to determine the size and capacity requirements of a control valve for any given
application, how actuators and positioners drive the control valve and how the type of valve influences the costs.
For selecting the right valve for a process system, one should: ensure that the process requirements are properly
defined, calculate the required flow capacity over the operating range, determine any limiting or adverse conditions
such as cavitation and noise and know how to deal with these, know how to select the valve that will satisfy the
constraints of price and maintainability whilst providing good process control performance [3].

2. STEPS IN CONTROL VALVE SIZING AND SELECTION

The basic steps in control valve sizing and selection are presented below [2] [4]-
The first step in control valve selection involves collecting all relevant process data.
Next, the size of the valve is required; select the smallest valve Cv that satisfies the maximum Cv requirement.
While performing these calculations, checks should be made regarding flashing, cavitation, sonic flow and Reynolds
number to ensure that the proper equation and correction factors are used. As many difficulties occur due to
oversized valves as to undersized valves. But adding lots of “safety factors” will result in a valve that is nearly
closed during normal operation and has poor rangeability.

* pkbcuet@yahoo.com
2|A u t h o r e t . a l . , I C E R I E 2 0 1 3

The trim characteristic is selected to provide good performance; goals are usually linear control loop behavior
along with acceptable rangeability.
The valve body can be selected based on the features and the typical availability. Note that the valve size is
either equal to the pipe size or slightly less. When the valve size is smaller than the process piping, an inlet reducer
and outlet expander are required to make connections to the process piping.
After that, the actuator should select to provide sufficient force to position the stem and plug.
Finally, auxiliaries can be added to enhance performance. A booster can be increase the volume of the
pneumatic signal for long pneumatic lines and large actuators. A positioner can be applied to make the response
faster and precise control or for high actuator force. A hand wheel is needed for manual operation of the valve.

3. PROCESS DATA AND VALVE TYPE SELECTION

3.1 Process Data

All process data that are relevant for selecting proper control valve should collect. The process data such as: process
fluid, temperature (operating and design), operating pressure (min and max), inlet pressure, outlet pressure, flow rate
(min and max), viscosity, corrosiveness, compressibility factor, allowable sound pressure, downstream pipe,
upstream pipe, pipe material, pipe connection and power failure position. The piping size must be set prior to valve
sizing, and determining the supply pressure.

3.1 Flow Characteristics Selection [1-5]

All control valves have an inherent flow characteristic that define the relationship between ‘valve opening’ and flow
rate under constant pressure condition. Valve opening for globe valve is up and down movement of the plug relative
to the seat and for rotary valve (like ball or butterfly) is lateral movement of the plug relative to the seat. Here in
table 1 some guidelines that are helpful in deciding which type of flow characteristic is best-suited for a particular
application. These are guidelines only, and should not be taken as absolute recommendations:

Table 1: Flow characteristics of control valve according to application

Characteristics Linear Equal Percentage Quick Opening
Suitable Process type Slow process Fast process Batch or semi-continuous
processes
Rangeability Requirement Linear proportional High rangeability Instantly large flow required
Pressure drop Major portion of the Major portion of the
system pressure drop is system pressure drop is
through the valve not through the valve
Control loop Liquid level or flow T and Pr. control Frequent on/off service, for
control safety or deluge systems

For specific application on flow, pressure and level the following should be considered.
Pr. Control Flow Control Level Control

Compressible Liquid
Fluid Fluid With √ ∆P Load ∆P ∆P Load
extractor
No
Yes
Equal %
Valve in series No Valve in
∆P FL Constant Increase
Down stream Yes or bypass bypass >2~1
<20NL
pipe lie< 100ft No No Yes
Flow Yes
No range Linear Quick
wide Equal %
Equal % opening
Or having receiver,
Linear Linear small
distributor ∆P-constant pr. drop, FL- full load, NL-no
load
Fig. 1: Flow diagram for flow characteristics selection
3|A u t h o r e t . a l . , I C E R I E 2 0 1 3

For variation of the process system, requirement of specific valve type is very important. Selection of proper valve
type ensures desired performance of the final control element that is control valve. In table 2 different features of
commonly used control valve type: gate, ball, globe, butterfly and diaphragm are described to get a clear
understanding to select the specific valve that best match to the prerequisite.

Table 2: Selection of control valves by considering general features of each type.

Gate Plug (Ball) Globe Butterfly Diaphragm
Type of On/off (Sliding) On/off (Rotary) Throttling Throttling Throttling
Service
Best Suited Quick opening Quick opening, Linear and Equal Linear and Equal
Control Linear percentage percentage
Advantages High capacity, Compact design Good sealing, Light, economical High capacity,
Tight shutoff, Low cost, Low Efficient specially for large size, low cost, self
Low cost, leakage & maint. throttling, Precise Minimal pressure loss, cleaning
Little resistance High capacity, flow control, High throughput actions, can
to flow Lightweight, Available in capacity, Smaller shaft handle
Good rangeability multiple ports, and actuator corrosive fluids
Tight shut-off Good rangeability
Disadvantages Poor sealing Poor throttling, High pressure Poor sealing,, Good Poor control,
characteristics Limited T range with drop, control up to 60 deg low rangeability
resillent seats, Choke More expensive opening, Tight shut-off short diaphragm
flow & Cavitation than others, requires special lining, life, not suitable
problems, Requires Low noise trim plus over-sized shaft & for high Pr drop
removal maintenance reduces capacity actuators, Lining application,
imposes T limitation slow response,
Sealing Gate face slides Radial seal shaped to Disk motion is Throttle blade is Diaphragm is
Mehtod parallel to the conform with ball perpendicular to mashed into mated forces onto
seat surface. surface valve seat. Only seal valve seat. Only
Gate and seal in contact is in fully contact at full
constant shear closed position closed position.
contract
Recommenda Fully Fully open/closed, Throttling service Operating torque is Diaphragm
-tion open/closed, non limited throttling, Flow regulation high so high actuating material should
throttling or Frequent force by the actuator select according
infrequent operations should ensure to the service
operation fluid T
Applications Oil, gas, air, Most liquids, high Liquid, vapors, Low pr applications Water treatment
slurries, heavy temperature, Most gases, corrosive Liquid, gases, slurries, service,
liquid, steam, suitable for handling substances, liquid with suspended Chemical and
non-condensing slurries, Not for slurries. solids. abrasive
gases & service with highly service.
corrosive liquids corrosive fluids.

Among the valve type described in table-2 globe is most popular and different types of globe valve have different
features which are given in table 3 to get a comparative overview.

Table 3: Characteristics of different types of globe control valves.

Double port Single port Three way Split body
Advantages High flow capacity and High rangeability, Good for blending and Good control
balance design require smaller tight shutoff, diverting applications, can characteristics,
actuator compare to single port reversible ports replace 2 tow-way valve tight shutoff,
valves, high rangeability, available, frequently in certain applications, simple, economic
reversible ports available, used size < 2 inch frequently used for T construction, easily
frequently used size > 2 inch control of heat exchanger maintained
Disadvantages High leakage rate at shutoff, Unbalance design Cannot control total flow, Limited pressure
low pressure recovery require relatively may need different size drop due to top
characteristics, not good for large actuator, ports, flow condition guided plug
high flow low pr. recovery should precisely known
characteristics
4|A u t h o r e t . a l . , I C E R I E 2 0 1 3

4. FLOW EQUATIONS FOR SIZING CONTROL VALVE

There are many code and standard that the valve manufacturers have followed for sizing of control valve. In this
paper the ISA standard is followed. The equations listed below identify the relationships between flow rates, flow
coefficients, related installation factors, and pertinent service conditions for control valves handling for
incompressible and compressible fluids. Flow coefficients may be calculated using the appropriate equation selected
from the ones given below [2]-

4.1 Sizing equation for incompressible fluids

Non-choked turbulent flow without attached fittings

Non-choked turbulent flow with attached fittings

4.2 Sizing equation for compressible fluids

Non-choked turbulent flow without attached fittings

Non-choked turbulent flow with attached fittings

Choked turbulent flow without attached fittings

Choked turbulent flow with attached fittings

4.3 Determination of correction factors

Piping geometry factor FP
The piping geometry factor FP is necessary to account for fittings attached upstream and/or downstream to a control
valve body. The FP factor is the ratio of the flow rate through a control valve installed with attached fittings to the
flow rate that would result if the control valve was installed without attached fittings and tested under identical
conditions which will not produce choked flow in either installation

Reynolds Number Factor, FR

The FR factor is determined by dividing the flow rate when non-turbulent flow conditions exist by the flow rate
measured in the same installation under turbulent conditions. Tests show that FR can be determined from the curves
given in Figure 4 using a valve Reynolds number calculated from the following equation [2]:

FF is the liquid critical pressure ratio factor. This factor is the ratio of the apparent vena contracta pr. at choked flow
conditions to the vapor pressure of the liquid at inlet temperature. At vapor pressures near zero, this factor is 0.96.
5|A u t h o r e t . a l . , I C E R I E 2 0 1 3

Expansion factor Y
The expansion factor Y, accounts for the change in density as the fluid passes from the valve inlet to the vena
contracta (the location just downstream of the orifice where the jet stream area is a minimum) [2]. It also accounts
for the change in the vena contracta area as the pressure differential is varied

Table 4: Symbol and its description that is used in flow equation calculation
C Flow coefficient (Kv, Cv) d Nominal valve size
Ci Assumed flow coefficient for iterative purposes Do Orifice diameter
FLP Liquid pressure recovery factor of a control valve without Fp Piping geometry factor
FL Combined liquid pressure recovery factor and piping geometry FR Reynolds number factor
M Molecular mass of flowing fluid Fγ Specific heat ratio factor
P1 Inlet absolute static pressure measured at point A Gg Gas specific gravity
P2 Outlet absolute static pressure measured at point B N Numerical constants
Pc Absolute thermodynamic critical pressure D Internal diameter of the piping
Pr Reduced pressure (P1 /Pc) D1 Internal diameter of upstream piping
Pv Absolute vapor pressure of the liquid at inlet temperature D2 Internal diameter of downstream piping
∆P Pr. diff between upstream and downstream pressure taps (P1 – P2) Fd Valve style modifier (see Annex A)
Q Absolute reference T for standard cubic meter FF Liquid critical pressure ratio factor
Rev Mass flow rate Tr Volumetric flow rate
T1 Ratio of pressure differential to inlet absolute pressure (ΔP /P1) Ts Valve Reynolds number
Tc Pr. diff ratio factor of valve without attached fittings at choked flow W Inlet absolute temperature
xTP Pr. diff l ratio factor of valve with attached fittings at choke flow x Absolute thermodynamic critical T
ρ1/ρo Relative density (ρ1/ρo = 1.0 for water at 15°C) xT Reduced temperature (T1 /Tc.)
ζ Velocity head loss coefficient of a reducer or expander Y Expansion factor
ζ1 Upstream velocity head loss coefficient of fitting γ Specific heat ratio
ζ2 Downstream velocity head loss coefficient of fitting Z Compressibility factor
ζB2 Inlet Bernoulli coefficient v Kinematic viscosity
ζB2 Outlet Bernoulli coefficient ρ1 Density of fluid at P1 and T1

Fig. 2: Flow diagram for Cv calculation of control valve for incompressible fluid
6|A u t h o r e t . a l . , I C E R I E 2 0 1 3

Fig. 3: Flow diagram for Cv calculation of control valve for compressible fluid

Fig. 4: Reynolds number factor FR for (a) full size trim valves (b) reduced size trim valve
7|A u t h o r e t . a l . , I C E R I E 2 0 1 3

5. CONTROL VALVE BODY AND ACTUATOR SELECTION [1-5]

5.1 Valve body material and end connection selection

The most common materials used in control valve body are iron, bronze, carbon steel and alloy steel. Monel,
Hastelloy, aluminum and plastics are also used. Rubber and plastic liners are used on diaphragm valves and similar
materials are used for making tight closures on other body types. The factors which should consider during valve
body material selection are: service fluid, service condition (operating parameter such as temperature, pressure),
piping materials, corrosiveness, economy and flashing services. Body size under two inches usually have screwed
connection and size two inches and above are normally flanged with rised-flanges predominant.

5.2 Valve body seat (single seat or double seat construction) selection
It depends on the function of permissible leakage in the close position and/or force requirements needed for valve
actuation. Single seated valves with metal to metal seats might be 0.05% leakage or less but double seated valves
may range from 0.1~1%. If leakage rates of 2% cannot be tolerated single seated valves should be used. In double
seated valves having high velocity jet which cause erosive damage to the trim and valve body. So, size the valve so
that it seldom operates near the seat. Control valves should not be used to shut in a system.

5.3 Valve actuator selection

Factors that should consider for selecting the actuators of a control valve are: pressure drop across the valve, process
hazards, valve size, response requirements, valve distance from controller, maintenance, existing plant practice and
availability of the operating medium. The spring diaphragm type is the most commonly used actuators. The piston or
cylinder types are also widely used. Electrohydraulic actuators are used when extremely fast actuation or maximum
power is required. Electric actuators are used in relatively few applications for on-off control in remote locations.

Table 5: Comparison of different types of control valve actuator

Spring and Diaphragm
Advantages Simple, easy to maintain,
economical, relatively
trouble free, safe for
hazardous areas and fast
enough for most application.
Disadvantages Large cumbersome actuators
required for some
application
Piston or Cylinder Electrohydraulic Electric
Exact positioning relative Extremely fast response, Economical when
to control signal, develops maximum air or gas is not
Relative fast response, power for actuation, available as a
large stem force required ensures accurate power medium
and hazard free. positioning of valve
Require high pr. air Expensive, hydraulic Slow response,
supply, more expensive, system require extremely more costly
sometime cumbersome to clean and well filtered actuators, more
achieve fail safe piping systems, more difficult to maintain
condition difficult to maintain in hazardous areas.

5.4 Valve positioner selection

Applications on which there is general agreement that positioner should be used include the following factors: split
range operation which require full valve stroke from some fraction of the controller signal, when maximum loading
pressure greater than 20 psi is required, when reversing action is required. There are also some other situations in
which positioners are often used are: valve size 6 inches and larger, where long transmission line exist, where the
pressure drop across the valve is too high, on high temperature applications, where excessive friction or in sludge
services. A positioner is used also to change the flow characteristics of a valve by contouring characterizing the cam.
It is a handy method of obtaining desired flow characteristics.

5.5 Selection of other mechanical features

Hardened Trim: Type 316 stainless steel is the most commonly used material for valve plugs, seats and stems.
Hastelloy, nickel, Monel and other alloys are used when corrosion or high operating temperature is a problem.
Hardened seating material is recommended for stem service having high pressure drop (>150psi), flashing services.
8|A u t h o r e t . a l . , I C E R I E 2 0 1 3

Seals: Bellows seals are used where no leakage along the stem can be tolerated.
Extension Bonnets: Are used for high temperature service to protect the packing from temperature (>450 ºF).
Packing and Lubrications: Teflon V-ring packing is the most common type of packing material used. It has self
lubricating qualities, requiring no lubrication. Packing material used for isolating from flowing fluid, reducing
friction and easy of replacement.
Guiding: Valve guiding types becomes more important with the increase of valve size. In terms of ruggedness and
dependability the preference valve guiding are: cage, top & bottom, top & port, port, top and stem.
Booster Relays: It is used to reduce time lags resulting from long transmission lines or where controller output are
insufficient to meet the capacity required for high demand devices such as large diaphragm actuators.
Hand wheels: It is mounted on control valves for manual operation in an emergency, during startup or in the event
of air failure or diaphragm rupture. They may also be used as limit stop to prevent full closure or opening of valves.
Valve noise problem: Valve noise associated with fluid transmission results primarily from mechanical vibration of
valve components, cavitation and aerodynamic noise. Cavitation is the formation and subsequent collapse of cavities
in a hydraulic system. Aerodynamic noise is due to the Reynolds stresses or sheer forces of turbulent flow.

5.6 Safety features consideration

In addition to the control function of control valves, they also serve as safety devices in processes. There are two
basic considerations relative to safety aspect: the position of the valve when other equipment fails and the position
of the valve, itself, if it fails. Fail safe is defined as the position of the valve (either open or closed) following loss of
its operating medium. As an example: Fuel gas valves to a furnace should fail closed to prevent gas flow when a
furnace shuts down for any reason.

6. CONCLUSION

In general, the reliability of a system is related to the complexity of that system. To ensure the reliability with using
simple course of action this paper may help the professional to size and select a proper control valve to ensure
precise control, safety and uninterrupted operation of the process plant in a systematic and economical way. As the
calculation and selection procedure outlined in this paper which is a very general and not for specific design case so
this study will greatly reduce the amount of up front engineering hours, though the final design must always be
guaranteed by the manufacturer.

7. ACKNOWLEDGEMENT

The authors would like to thank Mr. Sharafat Ali, Assistant General Manager, Department of Instrumentation &
Communication, Eastern Refinery Ltd., Bangladesh for his valuable guidelines to complete the task. Special thanks
to Md. Ali Zulquarnain, Member, Planning, Bangladesh Atomic Energy Commission for his valuable review.

8. REFERENCES

ISA Standard, “Flow Equations for Sizing Control Valves”, ISA-75.01.01-2007 (60534-2-1 Mod).
Emerson Process Management, “Control Valve Handbook”, 4th Edition, Fisher, www.EmersonProcess.com/Fisher
“CONTROL VALVE SELECTION AND SIZING (ENGINEERING DESIGN GUIDELINE)”, KLM Technology
Group, www.klmtechgroup.com
Trevor Bishop, Meredith Chapeaux, Liyakat Jaffer, Kiran Nair and Sheetal Patel, KBR “Easy Control Valve
Selection” www.cepmagazine.org November 2002.
PARCOL, “Handbook for Control Valve Sizing”, S.p.A. Via Isonzo, 2 - 20010 CANEGRATE (MI) – ITALY
General guideline and recommended practices of control valve operation and maintenance of Eastern Refinery
Limited, Chittagong, Bangladesh