Test Method For Pressure Independent Control Valves

Test Method for
Pressure Independent
Control Valves
BSRIA Technical Standard BTS No: 1
By Phil Stonard and Colin Judd
May 2012
Test Method for Pressure
Independent Control Valves
Issue date: May 2012
Issued by: BSRIA Limited

Old Bracknell Lane West,
Bracknell,
Berkshire RG12 7AH UK
Telephone: +44 (0)1344 465600
Fax: +44 (0)1344 465626
E: bsria@bsria.co.uk W: www.bsria.co.uk
This report must not be reproduced except in full without the written approval of an executive director of BSRIA. It is only
intended to be used within the context described in the text.
© BSRIA Page 3 of 15 BTS 1

TEST METHOD FOR PRESSURE INDEPENDENT CONTROL VALVES CONTENTS
CONTENTS
1. INTRODUCTION ........................................................................................................................... 6
1.1 Context ................................................................................................................................6
1.2 Purpose of document .............................................................................................................6
1.3 Background ..........................................................................................................................7
2. TEST METHODS ........................................................................................................................... 8
2.1 Rig set-up .............................................................................................................................8
2.2 Measured flow versus nominal flow......................................................................................10
2.3 Flow limitation test..............................................................................................................10
2.4 Control characteristic test .....................................................................................................11
2.5 Seat leakage test ..................................................................................................................12
2.6 Cycling test.........................................................................................................................13
2.7 Reporting format .................................................................................................................13
3. GLOSSARY OF TERMS ............................................................................................................... 14
Figure 1 A typical PICV ......................................................................................................................... 7
Figure 2 Basic schematic of the test rig .................................................................................................... 9
TABLES
Table 1 Test section piping requirements ................................................................................................ 9
APPENDICES
APPENDIX: A SAMPLE REPORT........................................................................................................ 15
CONTENTS
1. INTRODUCTION ........................................................................................................................... 6
2. OBJECTIVE ................................................................................................................................... 6
3. TEST ITEMS .................................................................................................................................. 6
4. INSTRUMENTATION .................................................................................................................... 8
5. TEST METHOD ............................................................................................................................. 8
5.1 Mesaured flow vs nominal flow ..............................................................................................8
5.2 Flow limitation test................................................................................................................8
5.3 Control characteristic test .......................................................................................................9
5.4 Leak Test..............................................................................................................................9
5.5 Cycling tests .........................................................................................................................9
6. RESULTS ....................................................................................................................................... 9
6.1 Flow limitation tests ..............................................................................................................9
6.2 Flow Limitation Graphs .......................................................................................................15
6.3 Flow CharActeristic Tests ....................................................................................................16
6.4 Flow Limitation Tests (after Cyclic tests) ..............................................................................24
7. CYCLING TESTS ......................................................................................................................... 25
8. OBSERVATIONS ......................................................................................................................... 25
FIGURES
Figure 3 View of valve................................................................................................................... 6
Figure 4 View of valve with fitted actuator ...................................................................................... 7
Figure 5 View of test rig 7

TEST METHOD FOR PRESSURE INDEPENDENT CONTROL VALVES
ACKNOWLEDGEMENTS
This standard test method has been written and produced by BSRIA in collaboration with industry.
BSRIA would like to acknowledge the assistance of the following organisations in the preparation of
this document:
Belimo Automation UK
Broen
Crane Building Services & Utilities
Danfoss
Frese
Herz Valves
Honeywell
Raxcrest Valves
SAV Systems
Skanska
TA Hydronics UK

TEST METHOD FOR PRESSURE INDEPENDENT CONTROL VALVES INTRODUCTION
1. INTRODUCTION
1.1 CONTEXT
Buildings with distributed heating and cooling loads often use water based distribution systems
(generally referred to as hydronic systems). In the bid to increase energy efficiency and cost
effectiveness, the use of variable speed pumping and two port control of room terminal devices has
produced systems within which the pressures vary dynamically. The industry response has been the
introduction of “Pressure Independent Control Valves” (PICVs) and “Pressure Independent Balancing
Valves (PIBVs), both of which provide several functions. Collectively, these two types can be
referred to as “Pressure Independent Balancing and Control Valves”. They can also be used in any
system where pressures vary.
For the purposes of this document, the term PICV is used to denote both PICVs and PIBVs.
PICVs are designed to provide a dynamic balancing function using a variable orifice component. In
addition, they may also be supplied with a modulating or on/off control function. Some PICVs also
incorporate isolation capability.
Key features are:
 Dynamic function that maintains a preset flow over a designated pressure differential range
 Adjustable preset flow
 A variety of actuators may be fitted
 Maintenance of control valve performance below the preset flow (within the designated pressure
differential range)
In the BSRIA guide, BG 2/2010 Commissioning Water Systems, it is stated that: “PICVs, sometimes
referred to as “combination valves”, combine the functions of a double regulating valve, differential
pressure control valve and two-port control valve within a single valve body”.
1.2 PURPOSE OF DOCUMENT

The purpose of this document is to describe a test method that simulates conditions that are
experienced in flow systems of incompressible fluids when using PICVs for flow regulation. It is
intended to cover measurements up to the manufacturer’s maximum permissible flow regulation and
the entire envelope of differential pressure that would be experienced across the valve tappings (where
provided).
The testing process monitors the regulation of fluid flow under either variable or constant pressure and
displays the valve characteristic which enables the inherent ability of the system to demonstrate
hydronic balance.
The results obtained from these tests can be compared with the designer’s specification and
calculations against manufacturer’s technical data and recommended pressure differences. Hence the
published data for supplying the required flow rates of fluid through a system can be analysed
effectively.
Note: The test method does not provide for an associated rating scheme. It is limited to obtaining
robust and repeatable test data by using a controlled set of conditions.

TEST METHOD FOR PRESSURE INDEPENDENT CONTROL VALVES INTRODUCTION
1.3 BACKGROUND
Prior to the publication of this standard, there was no standard test method that dealt specifically with
PICVs. Therefore the data quoted by different manufacturers covers a variety of pressure ranges and
characteristics. A test method is required to allow comparison of performance on a consistent basis.
PICVs can be applied to variable flow systems (e.g. AHUs, FCUs, chilled ceilings) and constant flow
systems (e.g. one-pipe central heating systems). The control valve can be used to ensure a controlled
flow passes through the system regardless of pressure experienced. Pressures may vary as a result of
varying flow rates in other parts of the system responding to varying loads.
Figure 1 A typical PICV
A typical PICV incorporates a differential pressure controller and a control valve element. The
differential pressure controller maintains the pressure difference across the control valve element. The
valve may be preset manually or via an actuator, where the presetting scale indicates values between
maximum rated flow and minimum prescribed flow. This minimum prescribed flow may be a
minimum stated flow or actually closed – this is design dependent.

TEST METHOD FOR PRESSURE INDEPENDENT CONTROL VALVES TEST METHODS
2. TEST METHODS
2.1 RIG SET-UP

The test facility shall consist of a pump system with a constant head, or other facility that provides the
same performance characteristics. Test circuits of differing pipe sizes can be accommodated on
common manifolds and separated using valves to allow flow through individual circuits. If required,
an additional pump can be incorporated to ensure sufficient pressure can be generated.
Flow shall be measured in units of l/s. Pressure difference shall be measured in units of kPa. Other
units may be reported on request.
The test specimen, which in this case is any PICV where test data is required, shall consist of a full-
scale model. The test section shall consist of a straight medium weight steel pipe on either side
adjacent to the test specimen. This is based on the specification set in BS EN 60534-2-3:1998, but with
shorter pipe lengths which will better demonstrate the capabilities of a PICV. The lengths of the steel
pipes are dependent on the nominal size of the test specimen pipe diameter connection – requirements
are stated in table 1. The unit under test shall be installed using its supplied fittings and in the
orientation specified by the manufacturer.
The inner diameter of the steel pipes shall be the same as that of the test specimen with a maximum
tolerance of  2%. This applies for diameters up to and including a size of DN 250 and a pressure
rating (which relates to valve body static limits) up to and including PN 100. The centreline of the test
section piping and the centreline of the inlet and outlet of the test specimen shall be aligned with a
maximum tolerance of 0.8 mm for a pipe size up to and including DN25, 1.6mm for pipe sizes DN32
through DN150 and 0.01 nominal pipe diameters for DN200 and larger. Note that the static pressure
limit of the valve body is often much greater than the stated maximum operating differential pressure.
This standard is concerned with operating parameters, not static pressure limit testing.
The test section and corresponding pipes shall be conduits running at 100 % capacity. They shall also
be clear of rust, scale or any other obstruction.
Each circuit shall have a calibrated magnetic flow meter in-line, with a digital readout. The flow
meter used shall provide a continual readout based on an average of several readings over a short
timescale within a minimum accuracy of  2% of the actual value. In order to maintain this accuracy,
the flow measurement device shall be calibrated as often as necessary. At the very least a calibration
should be completed on an annual basis.
Differential pressure shall be measured by means of a pressure transducer with a digital indicator
covering the range of 0-10 bar. The differential pressure is altered by varying the selected pump speed
using a combination of electronic inverter drives and bypass valves. Pressure tappings shall be fitted
on the test section, as shown in Figure 2, and using principles set within BS EN 60534-2-3:1998.
The basic fluid used in this test shall be water within a temperature range of 5C to 40C. Inhibitors
may be used to prevent or reduce corrosion and to prevent the growth of organic matter – provided
that the test results are not adversely affected.

Figure 2 Basic schematic of the test rig
l1+l2 l3+l4
Fluid flow Fluid flow

di i di i
Flow
measuring
device
l1 l2 l3 l4
Pressure taps
Table 1 Test section piping requirements

Symbol Description
l1 Greater than four times the nominal pipe diameter
l2 Equal to two times the nominal pipe diameter.
l3 Equal to four times the nominal pipe diameter.
l4 Greater than the nominal pipe diameter
Pressure tappings can be positioned on valves or pipework. Pressure tappings shall be provided within
the test section by using principles established within BS EN 60534-2-3:1998 and Table 1. The
tappings are on shorter pipe lengths than the standard requires, which will demonstrate better the
capabilities of a PICV. The pressure tap diameter shall be at least 3 mm and shall not be greater than
12 mm, or one-tenth nominal pipe diameter, whichever is the less as stated in BS EN 60534-2-3:1998.
The pressure tappings shall be circular and the edges clean and free from irregularities. The tappings
upstream and downstream shall be identical. Tappings are recommended to be installed on the side of
the pipework to avoid collection of air (if on top) or dirt (if on the bottom).

2.2 MEASURED FLOW VERSUS NOMINAL FLOW

This test indicates the accuracy of the nominal flow rate setting indicators as used by commissioning
engineers.
The ability to maintain a specific flow rate at a specific, representative differential pressure between
the minimum and maximum stated flow rates is demonstrated via the following procedure:
 Ensure (if fitted) the actuator performs no automatic function during this test.
 The valve flow rate shall be set to the minimum rated flow setting (as specified by the
manufacturer’s declared data) using the manually adjustable setting scale or limit stop. Particular
attention shall be paid to manufacturer instructions. Setting the valve to its minimum physical stop
will not necessarily set the valve to its minimum stated operating flow rate.
 Use the system pump(s) to provide a differential pressure of 100 kPa across the valve.
 Monitor the flow rate over a timescale of at least a minute. Once the flow rate has stabilised, the
value shall be noted. (Where the manufacturer has published a value, the test data can be
compared to the published data.)
 Repeat the flow measurements for at least four equally spaced different settings of flow rates up to
the maximum values.
 The procedure shall then be repeated with falling settings from maximum to minimum rated
settings.
The following variables shall be logged:
 Differential pressure at each increment of flow.

 Set (nominal from valve setting scale) and measured flow rates from minimum to maximum and
back to minimum at each increment.
The test shall be conducted three times and an average of all three tests taken. Using this data, the
measured data can be compared to the nominal settings provided by the manufacturer’s technical data.
2.3 FLOW LIMITATION TEST

This test indicates any inherent hysteresis in the valve flow rate performance as differential pressure
rises and falls across its full range (defined by the manufacturer).
Flow limitation (as differential pressure varies) is tested using the following procedure:
 The valve flow rate shall be set to the minimum rated flow setting (as specified by the
manufacturer’s declared data) using the manually adjustable setting scale or limit stop. Particular
attention shall be paid to manufacture instructions. Setting the valve to its minimum physical stop
will not necessarily set the value to its minimum stated operating flow rate.
 The differential pressure shall be raised from manufacturers minimum stated differential pressure
setting to 50 kPa in suitable stepped increments over a period of 10 minutes. BSRIA recommends
not greater than 5 kPa increments.
 The differential pressure shall be further raised from 50 kPa to the manufacturer’s stated
maximum in suitable increments over a period of 10 minutes. BSRIA recommends not greater
than 50 kPa.
 The differential pressure shall be reduced from the manufacturer’s stated maximum to 50 kPa in
suitable increments over a period of 10 minutes.

 The differential pressure shall be further reduced from 50 kPa to manufacturers minimum stated
differential pressure setting in suitable increments over a period of 10 minutes.
 Further to this, four equally spaced flow settings, ranging up to the maximum valve setting, shall
be set and the pressure varied as above.

 Differential pressure from manufacturers minimum stated differential pressure setting to the
manufacturer’s stated maximum and back to manufacturers minimum stated differential pressure
setting in suitable increments.
 Flow rate at each differential pressure increment from manufacturers minimum stated differential
pressure setting to the manufacturer’s stated maximum and back to manufacturers minimum stated
differential pressure setting.
 Set (nominal from valve setting scale) and measured flow rate from minimum to maximum and
back to minimum at each increment.
No actuator shall be fitted for this test.
This test shall be conducted three times and an average of all three tests taken to show how a set
“constant” flow rate varies with differential pressure variations. The results shall be displayed as a
graph showing the measured flow envelope between minimum, maximum and back to minimum
operating differential pressure. This can then be compared with the manufacturer’s technical data.
The knee of the graph will indicate the “start-up” of the valve operation.
2.4 CONTROL CHARACTERISTIC TEST

The purpose of this test is to analyse the flow characteristics of the valve with an actuator in full
operation. Therefore an actuator shall be fitted to the valve for this test and be in full operation.
The actuator may be a variable voltage type (e.g. 0-10 VDC), fixed voltage, variable time operation or
any other suitable configuration.
The flow characteristics shall be determined using the following procedure:
 The valve flow rate shall be set to the maximum rated flow setting (as specified by the
manufacturer’s published data) using the manually adjustable setting scale or limit stop. Particular
attention shall be paid to the manufacturer’s instructions – setting the valve to its maximum
physical stop will not necessarily set the valve to its maximum stated operating flow rate.
 The system shall be used to provide a differential pressure across the valve, with the valve actuator
set to 100% open. BSRIA recommend the selected pressure is maintained during test.
 A stepped signal shall be used (voltage, current or timed) to drive the valve from fully open to
fully closed and back to fully open in suitable increments, related to the valve characteristic. No
less than 20 increments shall be used in each direction with suitable time allowed to settle at each
increment (no less than 30 seconds per increment).
 If the characteristic is not obviously linear between applied signal and percentage flow, then more
readings should be taken at low signal values e.g. first 20%
 The signal applied and resulting flow rate shall be recorded for each test increment.
 The test shall be performed for each flow rate at five equally spaced differential pressure settings
including the manufacturer’s stated minimum and maximum operational values.
 Further to this, four equally spaced flow settings, ranging down to the minimum valve setting shall
be specified.

 Nominal flow setting and actual flow rate.

 Differential pressure from minimum to maximum and at each increment.
 Signal applied and flow rate at each controller setting.
 The dwell time at each increment.
The results shall provide an indication of the percentage of flow in comparison to the manufacturer’s
rated values.
Note. Some valves operate normally closed and some normally open. Also, some actuators can have a
reversing function where they can be switched such that either 0 or 10 is the minimum control point.
Valve characteristics may be either equal percentage or linear.
2.5 SEAT LEAKAGE TEST

This test is based on BS EN 60534-4:2006 Industrial process control valves Part 4: Inspection and
routine maintenance.
The purpose of this test is not to prove service isolation but to demonstrate the capability to shut off
flow to the terminal or other device being controlled. This test shall be performed with the actuator
fitted and set to its closed setting.
Note that BS EN 1349 is sometimes quoted in manufacturers’ literature. This Standard states, in the
introduction – “The testing requirements of EN 60534 – 4 are basically the same, but the hydrostatic
test makes reference to EN12266-1 which is a harmonised European Standard.”
The test procedure used shall be that which is appropriate to the manufactures stated maximum
working differential pressure (test procedure 1 if DP is less than 350 kPa and test procedure 2 if the
differential pressure is equal to or higher than 350 kPa) and as described in the EN standard. The
measured leakage rate is used to define the Leakage Class achieved.
The test apparatus shall be of such a design that it does not subject the valve to externally applied
stress that could affect the results of the test. The pressure gauge shall comply with the requirements
for accuracy of BS EN 60534-4.
The following general conditions of test shall apply:
a) Valves and connections shall be purged of air when testing with a liquid.
b) To avoid the risk of freezing when the test medium is water, the range of temperatures for water
shall be between 5 and 40C. For the valve or ambient air, the temperature during the test shall
not be less than 7C.
c) No valve undergoing pressure testing shall be subject to any form of shock loading.
Internal linings or coatings that form a design feature of the valve are permitted.
 Flow setting.
 Differential pressure applied.
 The volume of water leakage.
Temperature of test fluid.

2.6 CYCLING TEST

This test is optional. The purpose of this test is to determine the ageing effect on the constant flow
components within the valve. This is done by subjecting the PICV valve to repeated pressure
variation cycles, and re-testing some of the performance characteristics after cycling.
The basic fluid used in this test procedure shall be water within a temperature range of 5C to 40C.
Inhibitors may be used to prevent or reduce corrosion and to prevent the growth of organic matter
provided that the test results are not adversely affected.
The actuator performs no automatic function during this test.
The test procedure shall be as follows:
 Secure the valve on a suitable test rig and completely fill the valve with water at atmospheric
pressure.
 Attach pressure gauges (of certified accuracy that have been calibrated to zero or to datum point)
to the tappings.
 Start the test using the mid-range of flow setting and zero differential pressure. Raise the pressure
to the maximum permissible differential pressure as specified by the manufacturer in a time period
of less than 10 seconds.
 Decrease the differential pressure back to the minimum value, also within 10 seconds; this can be
referred to as one cycle.
 Repeat the test procedure a minimum of 10,000 times.
The following shall be recorded at the start and end of the test period and during the test at intervals of
no more than 1 hour:
 Inlet pressure.
 Pressure differential across the pressure taps.
 Fluid inlet temperature.
 Nominal Flow setting.
 Differential pressure from minimum to maximum.
 The time at which each item of data is logged.
 Any physical visible deformation.
When the cycling testing has been completed, the flow limitation test shall be repeated.
2.7 REPORTING FORMAT

An example report is included in Appendix A which indicates the form of reporting that should be
used.

TEST METHOD FOR PRESSURE INDEPENDENT CONTROL VALVES GLOSSARY OF TERMS
3. GLOSSARY OF TERMS
Minimum setting – the lowest setting the valve is physically capable of being set to. Note that the
valve may not operate correctly at this setting.
Minimum operating setting – the setting stated by the manufacturer. This defines the lowest flow
rate setting at which the valve will function correctly. This may not be the ‘Minimum setting’.
Maximum setting -the highest setting the valve is physically capable of being set to. Note that the
valve may not operate correctly at this setting.
Maximum operating setting – the setting stated by the manufacturer. This defines the highest flow
rate setting at which the valve will function correctly. This may not be the ‘Maximum setting’.
Pressure independence – The ability of the valve to maintain a set flow rate across the manufacturers
stated operating differential pressure range.
Valve characteristics - See ASHRAE’s 2008 publication, HVAC and Systems Handbook (Chapter
46, page 8), which explains linear as giving a straightforward relationship between stem travel and
flow, which is also used for the bypass port on three port control whereas, an equal percentage gives
a straight forward relationship between heat output and stem travel, which is used for terminal devices.

TEST METHOD FOR PRESSURE INDEPENDENT CONTROL VALVES SAMPLE REPORT
APPENDIX: A SAMPLE REPORT

PICV Tests
Report Number 12345/1
Carried out for

A Company Ltd
By Phil Stonard
June 2011

PICV Tests
Carried out for:
A Company Ltd
Any Street
Any Town
Shire
A12 1BC
Contract: Report 12345/1
Date: 10 June 2011
Issued by: BSRIA Limited

Old Bracknell Lane West,
Bracknell,
Berkshire RG12 7AH UK
Telephone: +44 (0)1344 465600
Fax: +44 (0)1344 465626
E: bsria@bsria.co.uk W: www.bsria.co.uk
Compiled by: Approved by:

Name: Name:
Title: Title:
This report must not be reproduced except in full without the written approval of an executive director of BSRIA. It is only
intended to be used within the context described in the text.

SAMPLE REPORT SUMMARY
SUMMARY
This report concerns flow and pressure tests conducted on a Pressure Independent Control Valve
(PICV). The work was commissioned by insert company name and was conducted during insert dates
of testing at insert full location address.
The test was conducted by insert details of test engineer, test organisation name and address and any
details of witnesses.
The objective was to determine the flow characteristic and pressure independence function of the
valve, (optional text follows) both before and after multiple pressure cyclic tests.
Optional: This valve has/has not (delete as appropriate) been tested for isolation capability.
A brief summary of the results are shown below.
Full test results are contained within Section 6 of this report.
MEASURED FLOW VS NOMINAL FLOW
Test sample Nominal setting (l/s) Measured flow (l/s) at 100 kPa Deviation %
Manufacturer’s e.g. 0.010 0.011 +10
nomenclature 0.025 0.025 0
0.050 0.052 +4
0.075 0.071 -5
0.100 0.095 -5
Status of test specimen to be stated eg Tested as received before cyclic tests of the pressure
independent component.
Measured flow is the mean of flow measurements taken with rising and falling applied pressure.
The valves showed/did not show (delete as appropriate) pressure independence across the
manufacturer’s stated working pressure range, with the flow deviating within X% (as determined from
tests) of the mean achieved flow.
In the operating pressure range as stated by the manufacturer the mean recorded flow was generally
within X% (as determined from tests) of the nominal.
The flow characteristics at 100 kPa when using the actuator produced characteristic curves – as shown
in Section 6 of this report. These are fundamentally linear/equal percentage/fast opening (delete as
appropriate) in nature.
The valve maintains a constant characteristic at all flow settings/ has a variable characteristic
depending upon the flow setting (delete as appropriate).

SAMPLE REPORT CONTENTS
CONTENTS
1. INTRODUCTION........................................................................................................................... 6
2. OBJECTIVE .................................................................................................................................. 6
3. TEST ITEMS ................................................................................................................................. 6
4. INSTRUMENTATION.................................................................................................................... 8
5. TEST METHOD ............................................................................................................................ 8
5.1 Mesaured flow vs nominal flow...........................................................................................8
5.2 Flow Limitation Test 0-500-0kPa ........................................................................................8
5.3 Control Characteristic test ..................................................................................................9
5.4 Leak Test ............................................................................................................................9
5.5 Cyclic tests..........................................................................................................................9
6. RESULTS ...................................................................................................................................... 9
6.1 Flow limitation tests ............................................................................................................9
6.2 Flow Limitation Graphs .....................................................................................................15
6.3 Flow Characteristic Tests .................................................................................................16
6.4 Flow Limitation Tests (after Cyclic tests) ..........................................................................24
7. CYCLIC TESTS .......................................................................................................................... 25
8. OBSERVATIONS ........................................................................................................................ 25
APPENDICES
APPENDIX: A MANUFACTURER’S DATA SHEET .............................................................. 26
FIGURES
Figure 1 View of valve........................................................................................................................... 6
Figure 2 View of valve and actuator ..................................................................................................... 7
Figure 3 View of test rig ........................................................................................................................ 7

SAMPLE REPORT INTRODUCTION
1. INTRODUCTION
This report concerns flow and pressure tests conducted on a PICV. The work was commissioned by
insert company name and was conducted during insert dates of testing at insert full location address.
The test was conducted by insert details of test engineer, test organisation name and address and any
details of witnesses.
2. OBJECTIVE
The objective was to determine the flow characteristic and pressure independence function of the
valve, (optional) both before and after multiple pressure cycling tests. All tests were carried out in
accordance with the BSRIA Test Methodology for PICVs. If there were departures from the Test
Methodology or additional tests, this section must make clear what these variations were.
3. TEST ITEMS
The item submitted for test was a pressure independent flow control valve for use on water systems.
It was designated insert valve model nomenclature and nominal size.
An actuator type insert actuator model nomenclature was fitted for the flow characteristic tests.
Provide general description of valve (e.g. the valve(s) consisted of an integral assembly and an
adjustable presetting scale). The scale was marked 0-100. A manually operated cap was also
provided to replace the actuator if required.
Manufacturer’s data sheets are included in Appendix A of this report.
Photographs and diagrams below show the general arrangement.
Figure 1 View of valve

SAMPLE REPORT TEST ITEMS
Figure 2 View of valve with fitted actuator
Figure 3 View of test rig

SAMPLE REPORT INSTRUMENTATION
4. INSTRUMENTATION
The instrumentation used consisted of: insert brief description of items used, operating range etc.
Item Ident No. Calibration due

Siemens Magflo 6000 124 24-04-11
Perflow digital manometer 432 22-12-11
5. TEST METHOD
The valve had a pair of integral pressure tappings. In addition, tappings on the pipework at two pipe
diameters upstream and 4 pipe diameters downstream of the valve were fitted to give a measure of
pressure drop across the valve using principles within BS EN 60534-2-3, “Industrial process control
valves-test procedures”, but with shorter pipe lengths.
Total pipe length was not less than 6 diameters upstream and 5 diameters downstream.
The valve was installed on the flow rig with straight lengths of medium weight steel pipe upstream and
downstream.
For achieving pressure variation, a variable speed pump was used to adjust the pressure drop across
the valve at each setting. At each valve setting, the differential pressure was raised in increments from
manufacturers minimum stated differential pressure setting to the manufacturer’s stated maximum and
back; this was performed over a period of 20 minutes with a minimum of 10 minutes to 50 kPa and 10
minutes to the manufacturer’s stated maximum and 20 minutes to return to manufacturers minimum
stated differential pressure setting on a similar basis.
Flow rate was recorded at each valve and pressure setting.
Graphs of flow rate vs differential pressure were then plotted to show the pressure independence.
Graph 6.2 also shows the ‘start up’ characteristic.
Tests were conducted in three stages as detailed below.
5.1 MESAURED FLOW VS NOMINAL FLOW

The valve was set using the manually adjustable collar to its minimum operational flow setting. A
differential pressure of 100 kPa was applied and the flow rate achieved noted. This was repeated for
25%, 50%, 75% and maximum flow setting. These were compared with the manufacturer’s quoted
values. No actuator was fitted during this flow test.
5.2 FLOW LIMITATION TEST
With no actuator fitted and the preset adjuster at 100% (maximum operational flow setting) the
pressure differential was raised in stages up to a maximum of insert Manufacturer’s maximum
permissible value and then back to zero to determine pressure independence and hysteresis. This was
repeated for preset values of 75%, 50% and 25% flow.

SAMPLE REPORT RESULTS
5.3 CONTROL CHARACTERISTIC TEST

The actuator was fitted and driven from its minimum to maximum and back to minimum in equal
increments. This is done with a pressure differential of 100 kPa being applied across the valve and
preset of 100% flow. This was then repeated at preset positions of 75%, 50% and 25% flow and
different settings of differential pressure (DP).
5.4 LEAK TEST

The valve was not declared a tight shut off device by the manufacturer and leak tests were not
therefore conducted. Alternatively, include text that makes clear this test was carried out and brief
note of how.
5.5 CYCLING TESTS

The valve was secured on a suitable test rig and completely filled with water at atmospheric pressure.
The valve was set to the mid-range of flow settings.
A calibrated pressure gauge was attached to the valve or rig tappings.
The test was started using the minimum operating differential pressure specified by the manufacturer
and then raised to the maximum permissible differential pressure as specified by the manufacturer in a
time period of less than 10 seconds. The pressure was then decreased back to the minimum value,
within 10 seconds; this constituted one cycle.
The process was repeated for a minimum of 10,000 times in a ‘cyclic’ process.
6. RESULTS
Tables of data are shown below, Followed by the graphical presentations of the results.
MEASURED FLOW VS NOMINAL FLOW

Test sample Nominal setting Measured flow (l/s) at 100 kPa Deviation
(l/s) %
Manufacturer’s e.g. 0.010 0.011 +10
Nomenclature
0.025 0.025 0
0.050 0.052 +4
0.075 0.071 -5
0.100 0.095 -5
Status of test specimen to be stated eg Tested as received before cyclic tests of the pressure
independent component.
Measured flow and deviation are the mean of the rising and falling applied pressure.
6.1 FLOW LIMITATION TESTS

Flow limitation pressure independence characteristic data covers a range of to be specified by the
manufacturer.
Graphs show rising and falling flow indicating any hysteresis.

6.1.1 Pressure independence characteristics 100% open
Actuator None Set 100%

Rated 0.150 l/s
Valve ∆P Flow Set
kPa l/s %
5 0.125 83
10 0.132 88
15 0.144 96
20 0.152 101
25 0.159 106
50 0.166 111
100 0.166 111
200 0.166 111
300 0.166 111
400 0.168 112
500 0.171 114
400 0.166 111
300 0.163 109
200 0.163 109
100 0.161 107
50 0.161 107
25 0.156 104
20 0.148 99
15 0.138 92
10 0.126 84
5 0.120 80


Rated 0.150 l/s
Valve ∆P Flow Set
kPa l/s %
5 0.110 73
10 0.115 77
15 0.120 80
20 0.128 85
25 0.134 89
50 0.136 91
100 0.136 91
200 0.136 91
300 0.136 91
400 0.136 91
500 0.137 91
400 0.134 89
300 0.134 89
200 0.133 89
100 0.133 89
50 0.133 89
25 0.125 83
20 0.122 81
15 0.117 78
10 0.112 75
5 0.107 71


Rated 0.150 l/s
Valve ∆P Flow Set
kPa l/s %
5 0.050 33
10 0.062 41
15 0.067 45
20 0.072 48
25 0.075 50
50 0.082 55
100 0.082 55
200 0.082 55
300 0.082 55
400 0.083 55
500 0.083 55
400 0.080 53
300 0.080 53
200 0.078 52
100 0.078 52
50 0.076 51
25 0.072 48
20 0.068 45
15 0.064 43
10 0.058 39
5 0.045 30


Rated 0.150 l/s
Valve ∆P Flow Set
kPa l/s %
5 0.020 13
10 0.025 17
15 0.030 20
20 0.034 23
25 0.039 26
50 0.039 26
100 0.039 26
200 0.039 26
300 0.039 26
400 0.040 27
500 0.041 27
400 0.037 25
300 0.037 25
200 0.035 23
100 0.035 23
50 0.033 22
25 0.033 22
20 0.030 20
15 0.026 17
10 0.020 13
5 0.015 10

6.1.5 Pressure independence characteristics minimum % open
Actuator None Set min%

Rated 0.150 l/s
Valve ∆P Flow Set
kPa l/s %
5 0.007 5
10 0.008 5
15 0.009 6
20 0.012 8
25 0.017 11
50 0.019 13
100 0.021 14
200 0.021 14
300 0.021 14
400 0.021 14
500 0.022 15
400 0.02 13
300 0.019 13
200 0.019 13
100 0.018 12
50 0.016 11
25 0.016 11
20 0.007 5
15 0.007 5
10 0.005 3
5 0.005 3

6.2 FLOW LIMITATION GRAPHS
Flow rate vs differential pressure
0.18
100%
75%
0.16 50%
25%
0.14 Minimum
0.12
Flow rate l/s
0.1
0.08
0.06
0.04
0.02
0
0 50 100 150 200 250 300 350 400 450 500
Pressure difference kPa

6.3 FLOW CHARACTERISTIC TESTS

Flow characteristic data is at a nominal 100 kPa (1 bar) differential pressure.
Graphs show rising and falling flow variation against applied signal indicating any hysteresis.
6.3.1 Flow characteristic data at full open
Actuator XA1 Set 100 open Rated 0.150 l/s

Valve Dp Flow
VDC kPa l/s % set
0 100 0.005 3.3
1 100 0.005 3.3
2 100 0.005 3.3
3 100 0.015 10.0
4 100 0.025 16.7
5 100 0.035 23.3
6 100 0.055 36.7
7 100 0.085 56.7
8 100 0.125 83.3
9 100 0.150 100.0
10 100 0.150 100.0
10 100 0.150 100.0
9 100 0.150 100.0
8 100 0.125 83.3
7 100 0.085 56.7
6 100 0.060 40.0
5 100 0.035 23.3
4 100 0.025 16.7
3 100 0.015 10.0
2 100 0.010 6.7
1 100 0.005 3.3
0 100 0.005 3.3

6.3.2 Flow characteristic data at 75% open
Actuator XA1 Set 75% open Rated 0.125 l/s

Valve Dp Flow
VDC kPa l/s % set
0 100.1 0.005 4.0
1 100.1 0.005 4.0
2 100.1 0.005 4.0
3 100.1 0.015 12.0
4 100.1 0.025 20.0
5 100.1 0.035 28.0
6 100.1 0.050 40.0
7 100.1 0.085 68.0
8 100.1 0.110 88.0
9 100.1 0.125 100.0
10 100.1 0.125 100.0
10 100.1 0.125 100.0
9 100.1 0.126 100.8
8 100.1 0.115 92.0
7 100.1 0.090 72.0
6 100.1 0.060 48.0
5 100.1 0.035 28.0
4 100.1 0.025 20.0
3 100.1 0.015 12.0
2 100.1 0.010 8.0
1 100.1 0.005 4.0
0 100.1 0.005 4.0


Valve Dp Flow
VDC kPa l/s % set
0 100 0.006 8.0
1 100 0.006 8.0
2 100 0.006 8.0
3 100 0.015 20.0
4 100 0.025 33.3
5 100 0.030 40.0
6 100 0.050 66.7
7 100 0.065 86.7
8 100 0.075 100.0
9 100 0.075 100.0
10 100 0.075 100.0
10 100 0.075 100.0
9 100 0.075 100.0
8 100 0.075 100.0
7 100 0.065 86.7
6 100 0.050 66.7
5 100 0.030 40.0
4 100 0.020 26.7
3 100 0.015 20.0
2 100 0.005 6.7
1 100 0.005 6.7
0 100 0.005 6.7


Valve Dp Flow
VDC kPa l/s % set
0 101 0.006 17.1
1 101 0.006 17.1
2 101 0.005 14.3
3 101 0.010 28.6
4 101 0.020 57.1
5 101 0.025 71.4
6 101 0.030 85.7
7 101 0.032 91.4
8 101 0.035 100.0
9 101 0.035 100.0
10 101 0.035 100.0
10 101 0.035 100.0
9 101 0.035 100.0
8 101 0.035 100.0
7 101 0.035 100.0
6 101 0.035 100.0
5 101 0.025 71.4
4 101 0.020 57.1
3 101 0.015 42.9
2 101 0.010 28.6
1 101 0.008 22.9
0 101 0.008 22.9

6.3.5 Flow characteristic data at minimum % open
6.3.6
Insert data here if tested at minimum %

Flow Characteristic Graphs
6.3.7 Graph of flow rate performance full open at 100 kPa
6.3.8 Graph of flow rate performance 75% open at 100 kPa


6.3.11 Graph of flow rate performance at minimum % open at 100 kPa
Insert graph here if tested at minimum
6.3.12 Graph of average flow rate performance at 100 kPa
For valve pre settings between min% and 100% open.

6.4 FLOW LIMITATION TESTS (AFTER CYCLIC TESTS)
Repeat of data tables and graphs following the format in Section 6.

SAMPLE REPORT CYCLING TESTS
7. CYCLING TESTS
Test item:
Number of items tested:
Start time:
Finish time:
No. of cycles:
Pressure range: (inlet and differential)
Temperature:
Flow range: Set to mid-range
Observations: All samples completed 10,000 cycles without visible damage.
8. OBSERVATIONS
Observations to be based on data in the report and any comparisons with manufacturer’s data must be
cross referenced to the data sheets in the Appendix.
Text from this section may be used to produce the Summary page.

SAMPLE REPORT APPENDIX A
APPENDIX A MANUFACTURER’S DATA SHEET

Test Method For Pressure Independent Control Valves

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Test Method For Pressure Independent Control Valves

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Test Method for

By Phil Stonard and Colin Judd

Issue date: May 2012

Issued by: BSRIA Limited

Telephone: +44 (0)1344 465600

Fax: +44 (0)1344 465626

© BSRIA Page 3 of 15 BTS 1

© BSRIA Page 4 of 15 BTS 1

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Key features are:

1.2 PURPOSE OF DOCUMENT

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Figure 1 A typical PICV

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2.1 RIG SET-UP

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Figure 2 Basic schematic of the test rig

Fluid flow Fluid flow

Table 1 Test section piping requirements

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2.2 MEASURED FLOW VERSUS NOMINAL FLOW

The following variables shall be logged:

 Differential pressure at each increment of flow.

2.3 FLOW LIMITATION TEST

© BSRIA Page 10 of 15 BTS 1

The following variables shall be logged:

No actuator shall be fitted for this test.

2.4 CONTROL CHARACTERISTIC TEST

The flow characteristics shall be determined using the following procedure:

The following variables shall be logged:

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 Nominal flow setting and actual flow rate.

2.5 SEAT LEAKAGE TEST

The following general conditions of test shall apply:

The following variables shall be logged:

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2.6 CYCLING TEST

The actuator performs no automatic function during this test.

The test procedure shall be as follows:

2.7 REPORTING FORMAT

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APPENDIX: A SAMPLE REPORT

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Carried out for

© BSRIA Page 16 of 15 BTS 1

Contract: Report 12345/1

Date: 10 June 2011

Issued by: BSRIA Limited

Telephone: +44 (0)1344 465600

Fax: +44 (0)1344 465626

Compiled by: Approved by:

© BSRIA Page 3 of 26 BTS 1

A brief summary of the results are shown below.

Full test results are contained within Section 6 of this report.

MEASURED FLOW VS NOMINAL FLOW

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It was designated insert valve model nomenclature and nominal size.

Manufacturer’s data sheets are included in Appendix A of this report.

Photographs and diagrams below show the general arrangement.

Figure 1 View of valve

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