Valve Sizing

Compressible Fluids Case

Chemical engineer
Juan Pablo Hernández
Currently, around the world, there are thousands of process plants which are in their
capability of producing a “X” product in a period of time.

One the process engineer’s main task is to ensure process conditions are under control, in
order to maintain safety (workers health, equipment’s safety, and avoiding environmental
pollutions)

And, of course, to ensure the specifications asked by clients.

 CONTROL VALVES

In order to meet process conditions and

quality of products, control valves are used.

This is the reason why designing control

valves play an important role on process
engineering.

In this presentation, a comparison of

designing control valves for compressible
fluids will be carried out by the use the
following methods:

• Hand made
• Fisher
• Aspen Hysys Figure 2. Fisher Control valve [2]
 ¡ATTENTION!

Designing control valves not always follows the methods shown in this presentation. Sometimes it is
necessary to have certain criteria acquired by the experience.
 STEPS TO CONSIDER BY EMERSON

According to Emerson’s control valve handbook, the steps to consider at the moment of designing control
valves for compressible fluids are:

1. Specify: Desired valve design, process fluid and service conditions (q or w, P1,∆P,Xactual, γ, ρ1 or Z1).
2. Determine the equation constants: N2,N5 and N6,N8 or N9 depending on the available process data
and system of units used.
3. Assume Cv and its corresponding Xtp value
4. Determine Fp (piping geometry factor) and Xtp(pressure drop ratio).
5. Determine Xchocked
6. Compare Xchocked and Xactual.(If Xactual is greater than Xchocked, then Xsizing= Xchocked. Else,
Xsizing= Xactual)
7. Calculate Y
8. Calculate Cv
9. Compare Cv and Cv assumed.(If Cv assumend ≈ Cv calculated (or in the Cv’ s range according to valve
size assumed), then Cv is correct. Else, assume a new Cv in step 3 (iterate using another valve size).
 EXAMPLE
Steam is to be supplied to a process at 250 psig.
The supply source is a header maintained at 500
psig and 260°C. It is assumed valve size is less
than NPS 6 (DN150). Determine the proper valve
and its opening percentage[6].

Figure 3. Control valve header [3]

Control valves have three typical flow characteristics: For more detailed information about Control valve flow characteristic.
Quick opening, Linear, and Equal percentage. This Please refer to Emerson control valve handbook. [4]

example states the linear Flow will be chosen.

 HAND MADE METHOD

1. Valve and process data 2. N’s contants

Linear Cage Globe Valve: Class 300 Since the example is carried out with English
Units
Process fluid: Super heated steam

Service conditions N constants

w(lb/h) 125000 N2 890
P1(psia) 514,7 N5 1000
P2(psia) 264,7 N6 63,3
∆P(psi) 250
Xactual(∆P/P1) 0,49
T1(°F) 500
ρ1(lb/ft3) 1,042
γ 1,33
 HAND MADE METHOD
3. Assuming initial Cv for a NPS 4(DN100) ED
valve with linear trim at 100% travel. [4]

𝐶𝑣 = 236
𝑋𝑇 = 0,69
 HAND MADE METHOD
4. Calculate Fp and Xtp
𝑑2 2
Since upstream and downstream are ෍ 𝐾 = 1,5(1 − 2)
𝐷
the same size:
𝑑2 42 2
𝐾1 = 0,5(1 − 2) ෍ 𝐾 = 1,5(1 − ) = 0,49
𝐷1 6,12
42
𝐾1 = 0,5 1 − = 0,16
6,12
4
𝑑
𝐾𝐵1 = 1 −
𝐷1
4
4
𝐾𝐵1 =1− = 0,82
6,1
 HAND MADE METHOD

5. Determine Xchocked 6. Compare 𝑋𝐶ℎ𝑜𝑘𝑒𝑑 and 𝑋𝑎𝑐𝑡𝑢𝑎𝑙 7. Calculate Y

Before calculating Xchocked is 𝑋𝐶ℎ𝑜𝑐𝑘𝑒𝑑 =0,64 𝑋𝑆𝐼𝑍𝐼𝑁𝐺
necessary to calculate 𝐹𝛾 𝑌=1− = 0,75
3 𝑋𝐶𝐻𝑂𝐾𝐸𝐷
𝑋𝑎𝑐𝑡𝑢𝑎𝑙 = 0,49
𝛾
𝐹𝛾 = = 0,95
1,4 Since 𝑋𝐶ℎ𝑜𝑐𝑘𝑒𝑑 > 𝑋𝑎𝑐𝑡𝑢𝑎𝑙
𝑋𝐶ℎ𝑜𝑐𝑘𝑒𝑑 = 𝐹𝛾 𝑋𝑇𝑃=0,64 𝑋𝑆𝐼𝑍𝐼𝑁𝐺 = 𝑋𝐶ℎ𝑜𝑐𝑘𝑒𝑑

BUT…¿WHAT IS A CHOKED FLOW AND WHEN DOES IT OCCUR?

Choked flow occurs when the velocity of fluid flowing through the
control valve reaches supersonic speed. [5]

It is the point at which increasing the ∆P, maintaining a constant

inlet pressure P1, yields no further increase in the flow rate. [6]
 HAND MADE METHOD

Cv for Globe Style Valve Bodies

8. Calculate Cv %
10 20 30 40 X … 100
NPS
𝑤 3 … 148
𝐶𝑉 = 4 173 … 236
𝑁6𝐹𝑃 𝑌 𝑋𝑆𝐼𝑍𝐼𝑁𝐺 𝑃1 𝜌1
This Cv calculated denotes that the valve is large enough to meet
𝐶𝑉 = 173 process conditions . There may be cases, where a more accurate
prediction is required. In such cases the required Cv should be
9. Compare Cv and Cv assumed recalculated using a new Xtp value(step 4) based on the last Cv
obteined previously, Cv=173.
𝐶𝑉 = 173
𝐶𝑉 𝑓𝑖𝑛𝑎𝑙 = 169
𝐶𝑉 𝑎𝑠𝑠𝑢𝑚𝑒𝑑 = 236
Opening= 66% open
If Cv had had a value greater than 236, then
the size of the valve would have been greater
than 4 NPS, propably 5 or 6 NPS … depending
on the Cv calculated.
 FISHER METHOD

This method follows the same algorithm proposed initially. Nevertheless, it is more sophisticated and takes
less time to calculate the Cv required and its corresponding opening percentage for conditions given.

The input needed to run the case is given in the previous example. Additionally, it must be supplied the
flow characteristics; in this case the flow characteristic chosen is linear.

In addition to the last exercise conditions, in this software, it can be estimated the Cv for each condition
given, which is much better, because it tell us the range in which the valve will be working in its inherent
conditions ( minimum, normal and maximum flowrates).

In process plants, generally, there are historical data related to: Flowrates, pressure and temperature
conditions; which are taken into consideration when designing control valves. This data let us ensure
that our future valve will be working properly due to data are based on the day-to-day plant
performance .
FISHER
METHOD
Fisher Results: Control valve
preliminary Datasheet and
Flow characteristics.
FISHER
METHOD
Fisher Results: Control valve
preliminary Datasheet and
Flow characteristics.
 ASPEN HYSYS METHOD

Aspen hysys also gives an idea about how will be the Cv of the valve studied. However, it is not as accurate as it
is calculated by companies dedicated to the design and construction of control valves.
One of the most knowns control valves companies are:
1. Emerson
2. Masoneilan
3. Samson
4. Taylor Valves
5. Etc.
In this example, in order to compare hysys with Fisher and handmade method, the opening percentage was
intentionally put in 66% to watch its corresponding Cv. Normally the Opening% in hysys is at 50% (default)
ASPEN HYSYS METHOD
FINAL RESULTS
 FINAL RESULTS

From the results given by the three methods, it must be highlighted that all results were not far different (for
this case).
However, if I had to decide from any of these, I would choose the results given by Fisher due to:
1. Time. It is important to keep in mind that when process engineers are in plant, most of the tasks must be
done as fast as possible. If the handmade method is tried, maybe it would give great results, but this
method besides taking much time, it’s more probably to do mistakes in its calculations.
2. Reliance. Fisher provides reliable information based on its control valves product catalog.

In the other hand, as said before, hysys control valve gives an idea about the Cv to be calculated. However,
results provided by Emerson are more reliable because are based in catalogs which are used by different
companies.
ABBREVIATIONS
AND
TERMINOLOGY

[4]
EQUATION
CONSTANTS

[4]
 REFERENCES

[1] A. Bhosale, «Control Valve Market: In-Depth Analysis with Key Market Players, Industry Size, Share,
Segmentation, Growth, Opportunity, Demand and Forecast to 2022,» Allied Market Research (AMR), USA.
[2] EMERSON, «Válvulas de control,» Fisher, 2020.
[3] A.L FIRE PROTECTION, «CUSTOM-WELDED-CONTROL-VALVE-HEADER,» East Hartford, 2020.
[4] EMERSON, Control Valve Handbook, Marshalltown,Iowa USA: Emerson Automatation Solutions, 2019.
[5] D. J. Westwater, «Choked flow valve with clamped seat ring». United States Patente 9 , 915 , 353 B2,
13 March 2018.
[6] EMERSON, «Understanding Choked Flow in Fisher™ Valves,» Emerson Automation Solutions, Iowa
USA, 2017.
¡Thanks for watching!

Juan Pablo Hernández Castillo

Contact:
• Email: juanpaheca@outlook.es
• Cel: +57 304 395 5569
• LinkedIn:
www.linkedin.com/in/juanhdezcastillo