Control Valves Handbook

CONTROL VALVES
CONTROL VALVES
CONTROL VALVES
CONTROL VALVES
HANDBOOK
Issue 2
2011-04
CONTROL VALVES HANDBOOK
PREFACE
In process automation, processes are managed by process control systems. Besides sensors, predom-
inantly final control elements are used. Their main components are the valve and the pneumatic actua-
tor as well as valve accessories, such as positioners, solenoid valves and limit switches. The extensive
product portfolio of the SAMSON GROUP, which consists of numerous modular components, enables
us to provide control solutions for almost any process engineering application. The resulting control
assemblies can work safely and reliably over many years without major maintenance work. This is
possible because we master all key stages: innovative design and production of modular valve
assemblies including smart valve accessories (such as positioners), the safe sizing based on the pro-
cess data and the reliable integration of positioners into the process control systems.
This SAMSON Control Valves Handbook showcases the competence of the SAMSON GROUP in all of
these areas. In addition to general information on standards, various valve styles (such as globe valves,
butterfly valves, ball valves) are described with their properties. What is the use of the best modular
valve assembly if no one knows which valve is best suited to the process requirements? It‘s all about
accurate sizing! SAMSON‘s R&D test bench at the Frankfurt headquarters has continually refined
sizing methods by carrying out fundamental research into sound level, cavitation, flashing, laminar
valve flow etc. Many of the findings have been included in the corresponding IEC and ISA standards.
The R&D test bench also contributed significantly to the development of the SAMSON valve sizing
software, including expert recommendations for tricky applications.
The numerous sizing examples highlight the expertise available at SAMSON for sizing valves, ap-
plied on a daily basis by SAMSON sales engineers all over the globe. An additional point of focus
is the chapter on reliable integration of smart positioners into process control systems.
I would like to express my thanks to numerous members of staff in the R&D and Sales divisions at
SAMSON. I am particularly indebted to the former SAMSON employees Hans Dieter Simon and
Holger Siemers who, when retired, took the time to compile all ideas and create what I consider to
be a high-quality valve handbook.
I hope you enjoy reading or consulting this handbook.
Dr. Jörg Kiesbauer

Member of the Executive Board responsible for Research and Development
Publisher: SAMSON AKTIENGESELLSCHAFT · MESS- UND REGELTECHNIK · Weismüllerstraße 3 · 60314 Frankfurt am Main · Germany
© Copyright 2010
Authors: Dipl.-Ing. Holger Siemers · Dipl.-Ing. Hans Dieter Simon
Issue 2
2011-04
Thanks
Notes of thanks
It would have been impossible to write such an extensive book without the help and
support of so many of our colleagues and other people. At this point, we would like
to repeat our gratitude to those people who have contributed to the first edition of
this handbook.
Our special thanks goes to Hans O. Engel who supplied us with the basics for this
handbook.
We received the help and support of so many people, some of whom studied and
suggested corrections for the unfinished chapters in their initial phase. Special thanks
goes to the following colleagues for their valuable input and support:
Name Department Name Department
Hans-Erich Grimm V Thorsten Muth V500
Günter Vogel V1 Theo Dobben V7
Guido König V1 Jürgen van Santen V72
Nelly Dickermann V12 Doris Lochte V109
Abey Mankulam V13
Stefan Czayka V13 Dr.-Ing. Jörg Kiesbauer E
Dr. Alberto Tamm-Reiners V13 Karl-Bernd Schärtner E4
Reinhold Lofy V16 Domagoj Vnucec E94
Dr. Thomas Karte E99
Uwe Vogel V4
Karlheinz Jürgens V42 Holger Eckholz E11
Markus Neufeld V42 Klaus Hörschken E12
Rainer Schwan V43 Peter Scheermesser E14
Axel Bug V43
Roberto Zin V47 Fiedler SC
Issue 2
2011-04
Our history
A flourishing company
In its over 100-year-long history, SAMSON has played an important role as an inventor,
pioneer and mediator in the development and manufacturing of instrumentation
and control technology.
Copyright © 2010 SAMSON AG · All rights reserved.
The manufacturer’s instructions on the use of any commercial product must be

followed at all times, even if in conflict with the information in this publication.
Brand names, trade names and trademarks mentioned in the reference application
may be brand names without special identification and are thus subject to legal rules
and regulations.
All nationally and internationally known brand names are herewith acknowledged
as such.
SAMSON AG cannot be held liable for any misuse, misappropriation, or violations of

patents or third party rights resulting from such misuse and probable consequences.
Neither SAMSON AG, nor the authors and translator of this handbook can be held
liable in any shape or form for any errors or omissions that may have occurred
during the diligent preparation of texts, charts, illustrations, etc.
SAMSON AG cannot be held liable for the illegal distribution, copying, misuse, or
other actions that violate the rights of the copyright owner(s).
Issue 2
2011-04
Table of contents
1. Introduction
1.1 Book introduction ��001
1.1.2. Scope of topics ��002
1.1.3. How to use this book? ��003
1.1.4. Structure and sequence ��003
1.2 SAMSON your Partner for Automation and Control ��004
1.2.1. An Innovative Leader in Global Markets ��005
1.2.2. Market segments ��006
1.3 Research and Development at SAMSON ��007
1.3.1. Optimized device integration �� 012
1.4 Production at SAMSON ��015
1.5 Quality assurance at SAMSON ��018
1.6 Logistic center and dispatch department ��020
1.7 SAMSON GROUP ��021
1.7.1. The associated companies �� 021
1.8 SAMSON’s Project execution ��030
1.9 Extract of reference installations ��031
1.10 Subsidiaries and Engineer and Sales Offices of SAMSON GROUP ��044
1.10.1. Extract of the subsidiaries ��045
2. Terms and definitions

2.1 Following a list of the most important valve standards: ��001
2.2 Valve technology ��012
2.2.1. Sectional drawings of Type 3241-7 �� 013
2.2.2. Sectional drawings of Type 3277 and Type 3271 with handwheel �� 014
Page I
SAMSON AG · MESS- UND REGELTECHNIK · Weismüllerstraße 3 · 60314 Frankfurt am Main · Germany

Phone: +49 69 4009-0 · Fax: +49 69 4009-1507 · E-mail: samson@samson.de · Internet: www.samson.de
Table of contents
2.2.3. Three-way Valve �� 017
2.2.3.1 Mixing service �� 017
2.2.3.2 Flow-diverting service �� 018
2.2.4. Metal bellows seal and insulating section �� 019
2.2.5. Valve bodies and styles ��020
2.2.6. Valve and component terminology ��025
2.3 Used symbols and units ��032
2.4 SI quantities and units of measurement ��044
2.5 Units derived from the SI system ��045
2.6 Formula symbols ��051
2.7 Conversion Tables (Examples of SI coherent derived units) ��052
2.7.1. Length SI derived units ��052
2.7.2. Area SI derived units ��055
2.7.3. Volume SI derived units ��057
2.8 Angle SI derived units ��061
2.8.1. Solid angle ��061
2.8.2. Weight and Mass SI derived units ��062
2.8.3. The World Clock - Time Zones ��064
2.8.4. Speed or velocity SI derived units ��067
2.8.5. Acceleration SI derived units ��068
2.8.6. Moment of Inertia SI derived units ��069
2.8.7. Density SI derived units ��069
2.8.8. Gage pressure, atmospheric pressure and absolute pressure �� 071
2.8.9. Pressure, stress SI derived units �� 072
2.8.10. Force SI derived units �� 075
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Table of contents
2.8.11. Torque SI derived units �� 076
2.8.12. Energy SI derived units ��077
2.8.13. Conversion table for Power units in relation to SI units �� 079
2.8.14. Dynamic viscosity SI derived units �� 081
2.8.15. Kinematic viscosity SI derived units �� 081
2.9 Flow SI derived units ��082
2.9.1. Temperature SI derived units ��083
2.10 List the mathematical symbols ��084
2.10.1. Greek alphabet in roman and italic type ��086
2.11 Terminology and Symbols in Control Engineering ��087
2.11.1. A pre-standard for the uniform representation of requirements of the

process control engineering (PCE) and data exchange between P&ID and
PCE tools. ��091
2.12 Prohibitive signs according to European Standards ��094
2.12.1. Personal Protective Equipment (PPE) ��094
2.12.2. Mandatory signs ��096
2.12.3. Escape and rescue signs for escape routes and emergency ��097
2.12.4. Fire protection symbols and additional symbols ��097
2.13 GHS ��098
2.13.1. Why is GHS needed? ��098
2.13.2. Hazard Classification ��098
2.13.3. GHS implementation by country (67 countries listed) ��099
2.13.4. ADR ��099
2.13.5. ADN ��099
2.14 Identification of pipelines according to the fluid conveyed. ��108
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Table of contents
3. Hydrodynamics
3.1 General considerations ��001
3.2 Basic conceptions ��001
3.3 Continuity equation ��002
3.4 Energy equation (Bernoulli equation) ��003
3.4.1. Static pressure energy px ��004
3.4.2. Potential energy (energy of the situation or height) ��004
3.4.3. Kinetic energy or speed energy ��004
3.5 Flow out of an open vessel ��006
3.6 Flow from a nozzle ��007
3.7 Impulse equation ��008
3.7.1. Vertical push against a wall ��009
3.8 Viscosity of a fluid ��010
3.9 Reynolds law of similarity ��014
3.10 Flow patterns ��015
3.11 Flow in piping systems ��016
3.12 Friction losses at laminar flow ��017
3.13 Friction losses at turbulent flow ��018
3.14 Special resistors in pipes ��019
3.15 Valves as pipe resistors ��022
3.16 Throttling of incompressible fluids ��023
3.17 Energetic consideration of the throttling process ��025
3.18 Operation of pumps in a pipe line system ��026
3.19 Pump and System Curves ��033
3.19.1. Parallel pumping ��033
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Table of contents
3.19.2. Series Pumping ��035
4. Aerodynamics
4.1 Properties of compressible fluids ��001
4.2 Ideal Gases ��001
4.3 Amount of heat ��002
4.4 Phase diagrams of ideal gases ��005
4.5 Energy and enthalpy ��007
4.6 Real gases and vapors ��008
4.7 Flow through nozzles ��009
4.8 Sonic velocity �� 011
4.9 Throttling by means of resistors �� 011
4.10 Thermodynamic throttling process in control valves ��013
4.10.1. Overheated Steam �� 013
4.10.2. Saturated Steam �� 014
4.10.3. Boiling Water �� 015
4.10.4. Valve throttling from thermodynamic point of view for Natural Gas: �� 016
4.11 Characteristics and special effects of throttling ��024
4.12 Energetic considerations of the throttling process ��027
5. Sizing equations for control valves

5.1 General ��001
5.2 Flow measurement at standard conditions ��001
5.3 Required process data ��002
5.3.1. Example 1) ��004
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Table of contents
5.3.2. Example 2) ��005
5.4 Calculation procedure for incompressible fluids ��008
5.4.1. Traditional sizing method ��008
5.4.2. Calculation method according to IEC 60534, part 2-1 �� 010
5.4.3. Influence of installed fittings (factor Fp) �� 010
5.4.4. Influence of vaporization (choked flow) �� 014
5.4.5. Influence of viscosity �� 018
5.4.6. IEC working equations for liquids ��020
5.4.7. Working equations for non-turbulent (laminar and transitional) flow ��022
5.4.8. Valve style modifier Fd ��025
5.4.9. Typical characteristics of various valve styles ��025
5.5 Calculation procedure for compressible fluids ��027
5.5.1. Traditional equations ��027
5.5.2. Calculation according to IEC 60534, part 2-2 ��028
5.5.3. Influence of installed fittings (Factor Fp) ��028
5.5.4. Consideration of expansion factor Y ��028
5.5.5. Consideration of real gases ��029
5.5.6. IEC working equations for compressible fluids ��030
5.5.7. Valve sizing with non-turbulent flow �� 031
5.6 Combined correction factors FLP and xTP ��031
5.7 Calculation at two-phase flow conditions. ��032
5.8 Multi-phase flow: liquid with dissolved gas ��036
5.9 Supercritical fluids above the critical point ��036
5.10 Natural gases and free definable mixtures according AGA 8 ��043
5.11 Natural gases LNG in liquid phase according GERG ��044
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5.12 Valve sizing for non-Newtonian fluids ��046
5.13 Other problems with regard to valve sizing ��048
5.14 Practical hints for the layout of control valves ��052
5.15 Use of suitable valve calculation software ��054
6. Control valve styles

6.2 Valves with linear stem motion ��004
6.2.1. Standard control valves ��004
6.2.2. Straight-trough type valve (four-flange-body) ��004
6.2.3. Standard valve (three-flange body) ��005
6.2.4. SAMSON pressure balanced plug ��006
6.3 Control Valves Series 3240 ��015
6.3.1. Control Valve with safety function Type 3241-1 and Type 3241-7 ��020
6.3.2. A modular design - best of class OPEX (Operational expenditure) �� 021
6.3.3. Bellows an additional component ��022
6.3.4. SAMSON Series 3240 Globe Valve Advantages �� 024
6.4 Series 3240 special valves for certain applications ��025
6.4.1. Control valves with forged steel or forged stainless steel bodies ��025
6.4.2. Control valve for PSA plants (Pressure Swing Adsorption) ��028
6.4.3. Micro-flow valve Type 3510 ��030
6.4.4. ON-OFF Valve Type 3351 ��043
6.4.5. Angle Seat Valve Type 3353 ��044
6.5 Series 3240 special Control valve for hygienic applications ��045
6.5.1. Approvals for hygienic applications �� 047
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Table of contents
6.5.2. Type 3347 Sanitary Micro-flow Valve ��052
6.5.3. Type 3347 for fruit juice industry ��053
6.5.4. Distribution Valve ��054
6.5.5. Three-in-one valve for Milk packaging ��055
6.5.6. Pneumatic Control Valve Type RG 41 ��056
6.5.7. For example beer breweries ��058
6.5.8. Lethal Service Valves Type 240 LS ��061
6.6 Control valve Series V2001 ��065
6.6.1. Control Valve Type 3522 (Little Tex) �� 075
6.6.2. Dump ON-OFF valve Type 3525 �� 078
6.7 Diaphragm valves Type 3345 ��081
6.7.1. Type 3345 Aseptic Diaphragm Valve DN 15 - 150 ��087
6.8 SAMSON valves for cryogenic applications ��088
6.8.1. World industrial gases demand to reach $30.4 billion in 2009 ��094
6.8.2. Extract from the SAMSON reference list. ��095
6.8.3. The Cold box ��097
6.9 Control valve Series 3250 ��098
6.9.1. High Pressure Valve Type 3252-1 / -7 ��104
6.10 Three-way valves Series 3240 and 3250 ��105
6.10.1. Mixing or flow-diverting valves �� 105
6.10.2. Design and principle of operation �� 107
6.10.3. Diverting or mixing valves for heavy-duty service in process engineering

��109
6.10.4. Mounting position �� 112
6.10.5. Mixing service, installation in the flow pipe. �� 114
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Table of contents
6.10.6. Mixing service, installation in the return flow pipe. �� 115
6.10.7. Flow-diverting service, installation in the flow pipe. �� 116
6.10.8. Flow-diverting service, installation in the return flow pipe. �� 117
6.10.9. Control Valve Type 3254-1 and Type 3254-7 �� 118
6.10.10. Control Angle valves Type 3256 �� 122
6.10.11. Angle Valve for Urea and Melamine Type 3256 S �� 125
6.10.12. Type 3258 valve with split body �� 130
6.10.13. Control Angle Valve Type 3259-1 and 3259-7 �� 132
6.10.14. Control Globe and Angle Valve Type RVG Flange �� 134
6.10.15. Control Globe and Angle Valve Type RVG with Multi-stage plug �� 136
6.10.16. For natural gas and offshore applications Valve Type VNG �� 137
6.11 Steam-converting valve Series 3280 ��141
6.11.1. Water bath desuperheater �� 143
6.11.2. Spray Water Nozzle for steam temperature reduction with continuous
control �� 147
6.11.3. Spray Water Nozzle for steam temperature reduction with continuous
control �� 148
6.11.4. Steam converting valves �� 152
6.11.5. Steam-converting Valve Type DUV-C3 ��154
6.12 Valves with PTFE or PFA lining ��156
6.12.1. Lined control valves �� 159
6.12.2. Chlorine industry ��169
6.13 Gate valves ��170
6.14 Knife Gate Valve ��171
6.15 Pinch- or clamp valves ��172
6.16 Advantages and disadvantages of commonly used linear control valves 174
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Table of contents
6.17 Valves with rotary stem (shaft) motion ��177
6.17.1. Ball Valves �� 178
6.17.2. Ball valves of stainless steel or precious metal �� 181
6.17.3. Ball valves seat ring and gasket principles: �� 183
6.17.4. Additional equipment and add-on pieces: ��190
6.17.5. Forged steel Ball Valves produced by Company Starline Spa �� 192
6.17.5.5 Floating �� 197
6.17.5.16 Trunnion ��208
6.17.5.23 Special Valves �� 215
6.17.6. Ball Valves with PTFE or PFA lining ��222
6.17.7. Universal material PTFE (Polytetrafluoroethylene) ��224
6.17.8. PTFE and PFA lining procedure ��225
6.17.9. Shaft Sealing – Fire-Safe ��229
6.17.10. Principle of operation of ball valves series 20a �� 231
6.17.11. Calibrated sealing rings for Series BR 20 and BR 26 Ball Valves ��232
6.17.12. V-Ball Valves ��233
6.18 Tank Bottom Valves ��238
6.19 Segmented ball valve ��243
6.20 Butterfly Valves metallic or with PTFE or PFA lining ��245
6.20.1. Butterfly valve styles ��248
6.20.2. Valves for Refineries „ESD“ ��262
6.20.3. Fire Lock ��265
6.20.4. Electropneumatic Positioner Type 3730-3 with HART® communication

ESD version ��266
6.21 Ball Valve “Trunnion mounted” for On/Off and Control Service ��267
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6.21.1. PTFE coated Ball and Butterfly Valves sizing and application limits. ��269
6.22 Rotary plug valves ��271
6.22.1. What is a rotary plug valve and what are its advantages? �� 276
6.22.2. What is typical for rotary plug valves �� 278
6.22.3. Solutions against abrasive fluids and mechanical wear �� 281
6.22.4. Solutions against abrasive media and mechanical wearing ��284
6.23 Valve style • Advantages • Disadvantages ��286
6.24 Special control-valves for power plants ��288
6.25 General tendencies and statistics ��317
7. Options and modifications of control valves

7.1 End connections ��002
7.1.1. Flange connections ��003
7.1.2. End connections for the Food Processing and Pharmaceutical Industries 006
7.1.3. Face-to-face dimensions ��008
7.1.4. Measures for flange facings ��009
7.1.5. Flanges according to European norm EN 1092-1:2001 �� 011
7.1.6. Flange Types from American and British specifications �� 012
7.1.7. NPS - Nominal Pipe Size and DN - Diameter Nominal �� 014
7.1.8. Equivalent of pressure ratings in ISO, ANSI, and EN �� 015
7.1.9. Flangeless connections �� 016
7.1.10. Threaded connections �� 018
7.1.11. Welded connections �� 018
7.2 Bonnet styles ��020
7.2.1. SAMSON Valve bonnets �� 021
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Table of contents
7.2.1.1 Steam line connection ��022
7.2.1.2 Bellows seal and insulating sections ��023
7.2.2. Cryogenic technology ��024
7.2.2.1 SAMSON Valves used in the filed of Cryogenics ��027
7.2.3. Heating jacket ��027
7.3 Packing and gaskets ��029
7.3.1. Stuffing boxes for control valves ��029
7.3.2. SAMSON standard packing ��032
7.3.2.1 SAMSON self-adjusting packing ��032
7.3.2.2 Stuffing box packing of Type 3241 ��034
7.3.2.3 Overview of the stuffing box packing forms ��035
7.3.3. Stuffing Boxes of Control Valves of Series 3240 �� 037
7.3.3.1 Form Standard ��037
7.3.3.2 Form A and B ��038
7.3.3.3 Form C ��039
7.3.3.4 Form H ��040
7.3.3.5 Form I �� 041
7.3.3.6 Form W ��042
7.3.3.7 NACE Packing ��043
7.3.4. Stuffing box packings for Type 3250 Valves ��044
7.3.4.1 Form Standard ��044
7.3.4.2 Form A ��045
7.3.4.3 Form B ��046
7.3.4.4 Form H ��047
7.3.4.5 Form S ��048
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7.3.4.6 NACE Packing ��049
7.3.5. TA-Luft (German technical regulations for clean air) ��050
7.3.5.1 Immission Indicators, Assessment Points, Grid Points ��050
7.3.5.2 Immission Values ��050
7.3.5.3 Emissions �� 051
7.3.5.4 Emission Ratio and Emission Reduction Ratio �� 051
7.3.5.5 Further reduction of fugitive emissions as the main aim ��052
7.3.5.6 International / national / company standards ��052
7.3.5.7 VDI 2440 ��052
7.3.5.8 DIN EN ISO 15848-1:2006 ��055
7.3.5.9 Additional requirements concerning the sealing system for control

valves ��058
7.3.5.10 ISO 15848-1 control valve versus isolating valve ��059
7.3.5.11 Valve diagnostics monitoring and diagnostics of the closed control

loop ��061
7.3.5.12 Graphite based packing systems ��064
7.3.5.13 Metal bellows seal ��077
7.3.5.14 Environmental concerns �� 078
7.3.5.15 Manufacturer's declaration �� 079
7.3.6. Control valve gaskets ��080
7.3.6.1 The following rules apply, in principle, for all flange gaskets: ��084
7.4 Screws (bolts) and nuts ��084
7.4.1. Product grades, property classes for bolts and nuts ��086
7.4.1.1 Eye bolts ��087
7.4.1.2 Material for Studs and Nuts ��088
7.4.2. Property classes, hexagon nuts with coarse threads ��089
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7.4.3. Hexagon nuts with coarse threads, Type 1 ��089
7.5 Control valve trims ��090
7.5.1. The most common trim types for globe valves ��091
7.5.2. Noise Attenuation Gaseous Medium – Multihole Plug ��094
7.5.3. Single seated version and pressure balanced version ��096
7.5.3.1 Screwed-in seat versus cage retained seat design ��097
7.5.3.2 Seat/Plug Sealing Design ��098
7.5.3.3 Leakage Classes acc. DIN EN 60534-4:2006 ��099
7.5.3.4 AC-Trims ��100
7.5.4. Valve characteristic and rangeability �� 102
7.5.4.1 Inherent rangeability �� 103
7.5.4.2 Limits of rangeability �� 110
7.5.5. Flow characteristics ��111
7.5.6. Interchangeability of valve components �� 112
7.5.7. Criteria for the use of air purging in the actuator spring chamber �� 114
7.6 Typical hook-ups �� 114
7.7 Terms and definitions �� 119
8. Noise emissions of control valves

8.1 Overview of noise calculation standards ��001
8.1.1. List of major SAMSON AG modifications ��002
8.2 Decibel A, B and C ��003
8.2.1. The Definition of Decibel ��004
8.3 General considerations ��006
8.4 Legal rules ��009
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Table of contents
8.5 Causes of valve noise ��009
8.5.1. Aerodynamic noise �� 010
8.5.2. Hydrodynamic noise �� 010
8.5.3. Other causes of valve noise �� 010
8.6 Noise calculation for compressible fluids ��013
8.6.1. Valve noise prediction for compressible fluids �� 014
8.6.2. Valves with standard trims ��032
8.7 Noise calculation for incompressible fluids ��042
8.8 International task force developed the new IEC 60534-8-4 2005-08 ��052
8.8.1. Summary and outlook ��069
8.9 Other noise considerations ��078
8.9.1. Influence of fittings and the valve installation in the pipeline �� 079
8.9.2. Influence of downstream fluid velocity ��082
8.9.3. Insulation of pipeline ��082
8.9.4. Determination of the sound pressure level for several noise sources ��084
8.9.5. Sound power Lwa or sound pressure level Lpa? ��085
8.10 Measures and notes on noise reduction ��085
8.11 Object related noise abatement ��087
8.11.1. Primary measures for noise abatement ��088
8.11.2. Low noise valves ��088
8.11.3. Low noise globe valves for liquid applications with cavitation ��092
8.11.4. Principle of operation ��095
8.11.5. Low noise globe valves for gas- and vapor applications with Flow divider
��097
8.11.6. Low noise globe valves for gas- and vapor applications with perforated plug
��098
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8.11.7. Low noise globe valves for gas- and vapor applications with Silencer �� 100
8.11.8. Low noise rotary plug valve VETEC for Gas applications ��106
8.11.9. Low noise rotary plug valve VETEC for liquid applications with cavitation:
��109
8.11.10. Low noise butterfly valves for liquid applications with cavitation: �� 110
8.11.11. Low noise butterfly valves for gas applications: �� 115
8.11.12. Secondary measures of noise control �� 117
8.11.13. Diffuser Silencer �� 119
8.12 Noise specific ratings of control valves ��122
9. Control valve actuators

9.1.1. Actuator types ��001
9.1.2. Symbols and units for the calculation of Actuators ��002
9.2 Pneumatic actuator with a linear or rotational movement ��005
9.2.1. Pneumatic diaphragm actuator ��005
9.2.1.1 Forces in valve and actuator ��007
9.2.2. Lay-out of a suitable valve actuator �� 010
9.2.3. Required actuator thrust for globe valves �� 011
9.2.4. Dynamic forces need to be considered in case of flow to close tendencies

�� 013
9.2.5. Calculation and selection of an actuator �� 019
9.2.5.1 General notes for the calculation and selection of actuators �� 019
9.2.6. Fail-safe action �� 021
9.2.6.1 Major application cases ��022
9.2.6.2 Flow force ��022
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Table of contents
9.2.6.3 Sealing, friction and other forces ��024
9.2.6.4 Actuator force Fa in all cases of (a) to (f) Chapter 9.2.6.1 ��025
9.2.6.5 Safety factors to actuator sizing ��028
9.2.6.6 Calculation examples (pressure balance): ��029
9.2.6.7 Calculation of the Hysteresis: ��032
9.2.6.8 Required actuator torque for rotary valves ��032
9.2.6.9 Actuator torque for standard butterfly valves ��033
9.2.7. The main group of the pneumatic diaphragm linear actuators ��036
9.2.8. Technical data for Packing and Plug stem diameter ��038
9.2.9. Technical data for additional handwheel ��038
9.2.10. Mechanically adjustable bidirectional travel stop ��039
9.2.11. Manual operation ��040
9.2.11.1 Pneumatic actuator Type 3277 with handwheel �� 041
9.2.11.2 Hand-operated Actuator Type 3273 with side-mounted ��043
9.2.11.3 Hand-operated Actuator Type 3273 attached to Type 3241 Valve

��044
9.2.12. Actuator Selection with AC-Trim ��045
9.2.13. Control valves in case of fire ��046
9.2.13.1 Safety cartridge �� 047
9.2.13.2 Fire-Safe / Fire lock ��049
9.2.13.3 Simulation of a fire ��050
9.2.13.4 Reversible operating direction �� 051
9.2.13.5 Summary ��052
9.2.14. Overview of actuators Type 3271-52, 3271-5, and 3277-5 up to a diaphragm

area 120 cm2. ��053
9.2.15. Overview of actuators Type 3271 up to a diaphragm area 1000 cm2. ��060
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Table of contents
9.2.16. Overview of the actuators of 1400 cm2 up to a diaphragm area 2 x 2800

cm2. ��066
9.2.17. Overview of actuators Type 3277 up to a diaphragm area 1000 cm2. �� 070
9.2.18. Overview of Actuators Type 3371, 3372, Type 2780-1, and Type 2780-2 077
9.2.19. Actuators Type 2780-1, and Type 2780-2 �� 078
9.2.20. Pneumatic Actuators Type 3371 and Electropneumatic Actuators Type

3372 �� 081
9.2.20.1 Technical data · Pressures in psi and bar ��083
9.2.21. The cost-efficient positioner Type 3725 ��084
9.2.22. Operating travels for fail-safe action ��085
9.2.22.1 Operating travels for fail-safe action STEM EXTENDS ��086
9.2.22.2 Operating travels for fail-safe action STEM RETRACTS ��092
9.2.23. Pneumatic piston actuator ��097
9.2.24. Pneumatic Piston Actuator Type 3275 ��097
9.2.25. Principle of operation ��098
9.2.26. Mounting Servovalve actuators on SAMSON Series 3240 and 3250 Valves
��100
9.2.26.1 PD Pneumatic linear actuator ��100
9.2.26.2 Double Acting �� 101
9.2.26.3 Double Acting with Handwheel �� 101
9.2.26.4 Double Acting with Manual Gear �� 102
9.2.26.5 Double Acting with Manual Hydraulic Pump �� 102
9.2.27. Rack and pinion pneumatic actuator �� 108
9.2.27.1 AIR TORQUE delivery program ��109
9.2.27.2 Design ��111
9.2.27.3 Construction ��111
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Table of contents
9.2.27.4 Range of Options, �� 113
9.2.27.5 Quality Manufacturing �� 113
9.2.27.6 Accessories available �� 113
9.2.27.7 Multi-function indicator �� 114
9.2.27.8 Operating conditions �� 116
9.2.27.9 Operating function and direction of rotation �� 117
9.2.27.10 Torque diagram Double Acting actuators �� 118
9.2.27.11 Spring Return Actuator �� 118
9.2.27.12 Air Torque Actuator Sizing �� 121
9.2.27.13 Sizing information �� 122
9.2.27.14 4th Generation pneumatic actuator �� 124
9.2.27.15 Pneumatic actuator Model AT 051 �� 125
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Table of contents
9.2.27.29 Protections Levels for 4th Generation Actuator �� 139
9.2.27.30 Protections Levels for 4th Generation Actuator �� 140
9.2.27.31 Full compliance with worldwide specifications �� 141
9.2.27.32 Company Approvals �� 143
9.2.28. Rotary Actuator Type 3278 �� 144
9.2.29. Pneumatic actuators of company Pfeiffer-Armaturen GmbH �� 146
9.2.29.1 Multi - Turn Actuator - Pfeiffer Type BR 30a �� 147
9.2.29.2 Additional equipment and add-on pieces: �� 148
9.2.29.3 Pfeiffer AT - Quarter-Turn Actuator Series BR31a �� 149
9.2.29.4 Additional equipment and add-on pieces: �� 150
9.2.29.5 Safety position: �� 150
9.2.29.6 Air drive torque �� 151
9.2.30. Pneumatic actuators of company VETEC Ventiltechnik GmbH �� 152
9.2.30.1 Diaphragm or rotary actuators �� 153
9.2.30.2 Direction of flow, Actuator action, and Fail-safe position: �� 155
9.2.31. VETEC Actuator Type R (rolling diaphragm or rotary actuator) �� 156
9.2.31.1 Principle of operation: �� 158
9.2.32. VETEC Actuator Type AT (Rack and Piston actuator) �� 160
9.2.32.1 Principle of operation �� 162
9.2.33. New design features �� 165
9.2.33.1 Vetec Type 62.7 AT short pattern with flanges �� 165
9.2.33.2 Vetec Type 82.7 R short pattern with flanges �� 165
9.2.34. VETEC Actuator Type MN (rotary or diaphragm actuator) �� 166
9.2.35. VETEC Actuator Type MD (rotary or diaphragm actuator) �� 168
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Table of contents
9.2.36. VETEC Actuator Type MZ (rotary or diaphragm actuator) �� 171
9.2.37. VETEC Actuator Type S (rotary or diaphragm actuator) �� 174
9.3 Pneumatic single acting quarter turn scotch-yoke actuators ��177
9.3.1. Symmetrical scotch-yoke �� 179
9.3.2. Canted scotch-yoke �� 179
9.3.3. Scotch Yoke �� 180
9.3.4. Quarter-Turn Pneumatic Actuators �� 181
9.3.5. Quarter-Turn Pneumatic Actuators �� 182
9.3.5.1 Applications �� 183
9.4 Electric with a linear or rotational movement ��184
9.4.1. Electro-mechanical Actuators ��184
9.4.2. Electro-mechanical and electro-hydraulic actuator �� 186
9.4.2.1 Electric Actuator Type 5857 �� 188
9.4.2.2 Accessories for version with digital positioner �� 189
9.4.2.3 Additional electrical equipment ��190
9.4.2.4 Electrical connection �� 192
9.4.3. Controller with Electric Actuator Type 5757 �� 193
9.4.3.1 Application ��194
9.4.4. Electric Actuator Type 5724 and Type 5725 ��196
9.4.4.1 Type 5724 �� 197
9.4.4.2 Type 5725 �� 197
9.4.4.3 Examples of electrical actuator Type 5824/5825 with various control
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Table of contents
valves ��199
9.4.5. Electro-hydraulic actuator ��200
9.4.6. Electrohydraulic Actuators Types 3274-11 to -23 ��203
9.4.7. Electric Actuator Type 3374 ��209
9.4.7.2 Fail-safe action �� 211
9.4.8. Electric Actuator Type 3375 �� 214
9.4.9. Electro-mechanical Actuators - PSL Overview �� 216
9.4.9.1 PSL Electro-mechanical Actuators �� 219
9.4.9.2 PS-AMS The All-In-One Actuators �� 221
9.4.9.3 Optional Accessories ��224
9.4.9.4 Mounting the PSL Actuator onto the Valves SAMSON Series 3240,
3250, and 3280. ��225
9.4.9.5 Type of limit cut-off ��225
9.4.9.6 Force/stroke-dependent limit switch cut-off ��226
9.4.9.7 Stroke-dependent limit switch cut-off ��227
9.4.9.8 Electric Supply ��228
9.4.9.9 Wiring diagram ��228
9.4.9.10 Maximum thermal switch loading ��229
9.4.10. Electric actuators outside source ��230
9.4.10.1 Linear Actuator Type SAM ��232
9.4.10.2 Principle of operation ��233
9.4.10.3 Electrical connection ��235
9.4.11. Electronic actuators of Company AUMA Riester GmbH & Co. KG ��236
9.4.11.1 Multi-turn actuators SAR 07.2 to SAR 30.2 �� 237
9.4.11.2 Linear thrust unit LE 12.1 to LE 200.1 for multi-turn actuators ��239
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Table of contents
9.4.11.3 Range of application ��240
9.4.11.4 Mounting to valve �� 242
9.4.11.5 Actuators without integral controls (AUMA NORM) ��245
9.4.11.6 Actuators with integral controls ��245
9.4.11.7 AUMA MATIC AM ��245
9.4.11.8 AUMATIC AC ��246
9.4.11.9 Electric rotary-type actuator for control service (AUMA RIESTER

KG) �� 247
9.4.11.10 Electric rotary-type actuator for control service �� 249
9.4.11.11 Standard version ��250
9.4.11.12 Accessories ��250
9.4.11.13 Motor �� 251
9.4.11.14 AUMA MATIC ��254
9.4.11.15 Wiring diagram AM4R AUMA MATIC AM 01.1/AM 02.1 ��258
9.5 Explosion-protected actuator ��259
9.5.1. What is an explosion? ��259
9.5.2. What is explosion protection? ��259
9.5.3. ATEX Directive 94/9/EC ��259
9.5.4. Classification of potentially explosive atmospheres ��260
9.5.5. Zone/equipment category ��260
9.5.6. Explosion group/temperature class �� 261
9.5.7. How to achieve explosion protection? ��263
9.5.7.1 Increased safety (EEx e) ��263
9.5.7.2 Flameproof enclosure (EEx d) ��263
9.5.7.3 Constructional safety (c) ��264
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Table of contents
9.5.7.4 Who tests what? ��264
9.5.7.5 Auma Marking ��265
9.5.7.6 Electric actuators and non-electrical explosion protection ��266
9.5.8. Explosion-protected actuator ��269
9.5.8.1 Explosion-protected actuator from Company SCHISCHEK �� 270
9.5.8.2 Accessories and special designs (additional price) �� 272
9.5.8.3 Ex-d valve actuators without spring return, 24 to 240 V AC/DC

Type ExRun �� 273
9.5.8.4 Ex-n valve actuators without spring return, 24 to 240 V AC/DC
Type RedRun �� 274
9.5.8.5 Wiring diagram of Type ExRun �� 276
9.5.9. Type 3510 Micro-flow Valve with explosion-proof electric actuator �� 278
9.6 Hydraulic with a linear movement ��279
9.6.1. Hydraulic Scotch Yoke Valve Actuators ��280
9.6.1.1 Reliability by Design �� 281
9.6.1.2 Safety by Design �� 281
9.6.1.3 High Performance by Design �� 281
9.6.1.4 Override Options �� 281
9.6.1.5 Key Design Features ��282
9.6.1.6 VETEC Rotary valve with Pleiger hydraulic actuator ��283
9.6.2. Hydraulic- actuating systems of Welland & Tuxhorn AG ��284
9.6.2.1 Functions ��285
9.6.2.2 Design ��286
9.6.2.3 Setup of an electro-hydraulic Control Loop ��286
9.6.2.4 Hydraulic Servo-Systems - Establishment and Manufacturing ��288
9.7 Data Sheet for Control Valves according to DIN EN 60 534-7 ��289
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Table of contents
9.8 Data Sheet for Control Valves according to ISA Form S20.50. Rev. 1 ��290
10. Control valve accessories

10.1 General ��001
10.2 Positioners ��001
10.2.1. Pneumatic Positioner- Electropneumatic Positioner ��004
10.2.2. Overview Pneumatic of (p/p) Positioners ��008
10.2.3. Overview Electropneumatic of (i/p) Positioners ��008
10.2.3.1 Pneumatic Positioner Type 3766 and

Electropneumatic Positioner Type 3767 ��009
10.2.3.2 Type 4763 Electropneumatic Positioner
Type 4765 Pneumatic Positioner �� 010
10.2.3.3 Type 3760 Electropneumatic Positioner and
Pneumatic Positioner �� 011
10.2.3.4 Type 3725 Electropneumatic Positioner �� 012
10.2.3.5 Type 3730-0 Electropneumatic Positioner �� 013
10.2.3.6 Type 3730-1 Electropneumatic Positioner �� 014
10.2.4. e/p-Signal converters (transducers) �� 015
10.2.4.1 Switch-off electronic function �� 017
10.2.4.2 Application of i/p signal transducers �� 018
10.2.4.3 Overview of e/p Converters ��020
10.2.4.4 Electropneumatic Converters for Direct Current Signals

i/p Converter Type 6111 �� 021
10.2.4.5 Electropneumatic Converter for direct current signals
i/p Converter Type 6116 ��022
10.2.4.6 Type 3766 Ex d Positioner with Type 6116 i/p Converter �� 024
10.2.4.7 Current-to-Pressure Converter Type 6126

Voltage-to-Pressure Converter Type 6126 ��025
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Table of contents
10.2.4.8 Electropneumatic Converters for DC Signals

i/p Converter Type 6127 ��026
10.2.4.9 Type 6150 and Type 6151 Converter modules ��027
10.3 Integration of analog devices into AS-Interface ��028
10.3.1. AS-Interface: Typical application 1 ��029
10.3.2. AS-Interface: Typical application 2 ��030
10.3.3. AS-Interface: Examples for “Slave and Actuator” �� 031
10.3.4. p/e-Converter ��032
10.3.4.1 Overview of p/e Converters ��033
10.3.4.2 Electropneumatic Converters for Pneumatic Signals

p/i Converter Type 6132 ��034
10.3.4.3 Electropneumatic Converters for Pneumatic Signals
p/i Converter Type 6134 ��035
10.3.4.4 Application examples ��036
10.4 Smart positioners and Electropneumatic Ex d positioners ��038
10.4.1. Overview of Smart positioners ��040
10.4.2. Overview of Electropneumatic Ex d positioners ��040
10.4.2.1 Type 3730-2 and Type 3730-3 Electropneumatic Positioner with

HART® communication �� 041
10.4.2.2 Type 3730-4 Positioner with PROFIBUS-PA communication ��042
10.4.2.3 Type 3730-6 Electropneumatic Positioner ��043
10.4.2.4 Ex d positioners Type 3731-3 Ex d Positioner

with HART communication ��044
10.4.2.5 Ex d positioners Type 3731-5 Ex d Positioner
with FOUNDATION™ fieldbus communication ��045
10.4.3. Smart valve positioners and their use in safety instrumented systems �� 047
10.4.3.1 Diagnostic capabilities �� 047
10.4.3.2 Implementation strategy ��048
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Table of contents
10.4.3.3 Scope of valve diagnostics �� 051
10.4.3.4 On/off valve diagnostics �� 051
10.4.3.5 Advanced ideas ��055
10.4.3.6 Diagnostics using smart positioners in association with IEC 61511

��058
10.4.3.7 Acronyms and abbreviations ��062
10.4.3.8 Relevant standards ��063
10.4.3.9 Terms and definitions ��063
10.4.3.10 EXPERT+ Valve diagnostics for Series 3730 and Series 3731
Positioners ��064
10.4.3.11 TROVIS-VIEW Operator Interface ��065
10.5 Limit switches and position transmitters ��066
10.5.1. Continuous feedback of valve position ��068
10.5.2. Feedback by means of limit switches ��068
10.5.3. Combined feedback equipment ��069
10.5.4. Automation for On/Off valves / Positioner / Solenoid valve / Limits witch /
Asset Management �� 070
10.5.5. Type 3738-20 Electronic Limit Switch �� 072
10.5.6. Type 3768 Inductive Limit Switch �� 073
10.5.7. Type 3776, with inductive or electric contacts and solenoid valve �� 074
10.5.7.1 Function �� 075
10.5.7.2 Limit switch with inductive pick-ups �� 075
10.5.7.3 Limit switch with inductive double proximity switch �� 075
10.5.7.4 Limit switch with electric microswitches �� 076
10.5.7.5 Limit Switch Type 3776 - Examples of application �� 077
10.5.8. Type 4744 Electric Limit Switch for hazardous areas ��080
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Table of contents
10.5.9. Type 4746 Electric or Pneumatic Limit Switch �� 081
10.5.10. Type 4747 Electric Limit Switch ��082
10.5.11. Type 4748 Analog Position Transmitter ��084
10.5.12. Mounting Cylindrical Inductive Proximity Switches ��085
10.6 Solenoid valves ��087
10.6.1. Function ��089
10.6.1.1 Solenoid valves with single actuation ��089
10.6.1.2 Solenoid valves with double actuation ��090
10.6.1.3 Circuit symbols of DIN ISO 1219-1:2006 ��090
10.6.2. Type 3701 Solenoid Valve ��099
10.6.3. Type 3962 Solenoid Valve ��100
10.6.4. Type 3963 Solenoid Valve �� 101
10.6.5. Type 3964 Pilot Valves �� 103
10.6.6. Type 3965 Solenoid Valve Island ��104
10.6.6.1 Base modules ��109
10.6.6.2 Pneumatic connection modules ��111
10.6.6.3 Electric connection module �� 112
10.6.7. Type 3967 Solenoid Valve �� 113
10.7 Supply Pressure Regulator �� 115
10.7.1. Supply Pressure Regulator Type 4708 �� 118
10.7.2. Summary of SAMSON positioners and actuators with associated

Type 4708-xx Supply Pressure Regulator �� 123
10.7.3. Type 3999-009x Service Unit Model for purifying and controlling
compressed air �� 126
10.7.4. Type 3999-0096 Filter Regulator (SAMSOMATIC) �� 127
10.8 Pneumatic boosters ��128
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Table of contents
10.8.1. Principle of operation of Type 3755 Volume Booster �� 129
10.8.2. Mounting on control valves �� 132
10.8.2.1 Application Examples �� 135
10.9 Series 3710, Reversing Amplifier Type 3710 ��138
10.9.1. Principle of operation �� 140
10.10 Pneumatic air lock relay ��143
10.10.2. Typical applications �� 144
10.10.3. Type 3709 Pneumatic Lock-up Valve �� 145
10.11 Pneumatic Remote Adjuster ��146
10.12 Safety and Relief Valve ��148
10.13 Quick exhaust valve ��149
10.14 Filter-check valve ��150
10.15 Sun cover ��152
10.16 Junction box ��153
10.16.1. Description �� 153
10.17 Safety air tanks for instrument air ��154
10.17.1. General ��154
10.17.2. Function ��154
10.17.3. Sizing of safety air tanks for instrument air for double acting actuators � 156
10.17.4. Version �� 159
11. Application and selection criteria

11.1 Possibilities of fluid control ��001
Page XXIX

Table of contents
11.1.1. Throttling techniques ��002
11.1.2. Pumps with variable rotational speed ��003
11.1.3. Minimum differential pressure at the control valve ��005
11.1.4. Control valves today are converting links between budgets �� 010
11.1.5. Sources of planning mistakes �� 014
11.1.5.1 How much minimum pressure drop need a control valve? �� 014
11.1.6. Improved rules of thumb for energy saving applications. �� 015
11.1.7. Plant – and process design and valve manufacturer responsibility �� 017
11.1.8. Control valve characteristics ��022
11.1.9. Limits of de-bottlenecking: Case study: good travel, bad control �� 024
11.1.10. „Installed“ flow characteristic ��026
11.1.11. Practical hints for selecting a suitable valve characteristic ��026
11.1.12. Control valve gain ��029
11.1.13. Safety charges and travel limits ��033
11.1.14. Control technology considerations ��034
11.1.14.1 Tips for correcting unstable control loops ��036
11.2 Predicting control valve reliability problems ��036
11.2.1. Standard globe valves and rotary valves and their differences in general
regarding critical applications ��036
11.2.2. Critical valve outlet velocities for gas and vapors. ��039
11.2.3. The need for limitations of valve outlet velocities ��040
11.2.4. Trim outlet velocity not practical for standard globe and rotary valves. �� 041
11.2.5. Valves developed to preferred market segments and possible reliability

problems of overloaded valves. ��042
11.2.6. CFD flow calculation of the rotary valve and piping system ��043
11.2.6.1 Liquid CFD simulation ��044
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Table of contents
11.2.7. Limited outlet velocities to avoid troubleshooting ��045
11.2.8. CFD flow calculation the globe valve and piping systems with expansion
pieces. �� 047
11.2.9. Flow charts with good engineering methods in selecting valves for long
term reliability. ��050
11.2.9.1 Flowchart for liquids without and with cavitation ��050
11.2.9.2 Flowchart for flashing applications ��052
11.2.9.3 Long term reliability recommendations for gas, steam, vapors ��056
11.3 References: ��057
12. Selection of suitable materials

12.1 General ��001
12.2 Corrosion ��003
12.2.1. Uniform area corrosion ��006
12.2.2. Local corrosion ��006
12.2.3. Contact corrosion ��007
12.2.4. Intergranular and transgranular corrosion ��007
12.2.5. Stress corrosion ��009
12.2.6. Crevice corrosion ��009
12.2.7. Corrosion-erosion �� 010
12.3 Capability for resistance against wear & tear ��010
12.3.1. Cavitation �� 011
12.3.3. Erosion-Corrosion �� 015
12.3.4. Jet wear (erosion) through solid particles �� 016
12.3.5. Erosion by high speed droplets �� 017
12.3.6. Thermal erosion �� 017
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Table of contents
12.4 Passivation to combat corrosion ��018
12.4.1. Corrosion protection �� 019
12.4.2. Preventative actions for corrosion protection ��020
12.5 Surface treatment of SAMSON instruments ��020
12.5.1. Objective ��020
12.5.2. Scope of application �� 021
12.5.3. Regulations �� 021
12.5.4. Standard version �� 021
12.5.5. Coated surfaces �� 021
12.5.6. Uncoated surfaces ��022
12.5.7. Surface preparation ��022
12.5.8. Degreasing and pickling ��022
12.5.9. Zinc phosphating ��022
12.5.10. Galvanizing and passivating ��022
12.6 Application conditions ��022
12.7 Strength and fatigue strength of materials ��030
12.7.1. Material testing methods ��033
12.8 Materials for valve body and valve bonnet ��037
12.9 Frequently applied special materials ��038
12.9.1. New austenitic steels ��039
12.9.2. Highly corrosion resistant materials on nickel basis �� 041
12.9.3. Titanium and its alloys ��044
12.9.4. Tantalum materials ��044
12.9.5. Other special materials ��044
12.10 Common trim materials ��046
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Table of contents
12.10.1. Chromium steels ��046
12.10.2. Hard alloys (e.g. tungsten carbide) �� 047
12.10.3. Ceramics �� 047
12.10.4. Materials for guide bushings / valve stems �� 051
12.11 Materials for valve linings ��051
12.12 Comparative materials - Casting materials ��055
12.12.1. Comparative materials - Special casting materials ��056
12.13 Comparative materials - Forging materials ��057
12.13.1. Comparative materials - Special forging materials ��058
12.14 Comparative materials - Bar materials ��059
12.14.1. Comparative materials - Special bar materials ��060
12.15 Comparative materials - Plate materials ��061
12.15.1. Comparative materials - Special plate materials ��062
12.16 Comparative materials - Piping materials EN ��063
12.16.1. Comparative materials - Special piping materials EN ��063
12.17 Comparative materials - Piping materials ANSI ��064
12.17.1. Comparative materials - Special piping materials ANSI ��064
12.18 Comparative materials - Fitting materials ANSI ��065
12.19 Comparative materials - Bolting materials EN ��066
12.19.1. Comparative materials - Special bolting materials EN ��066
12.20 Comparative materials - Bolting materials ANSI ��067
12.20.1. Comparative materials - Special bolting materials ANSI ��067
12.21 Materials for control valve accessories ��068
12.21.1. Aluminum alloys ��068
12.21.2. Thermoplastics ��069
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12.22 Glossary ��071
13. Safeguarding and fail-safe requirements

13.1 Failure position in the case of auxiliary power loss ��001
13.2 Internal tightness of the control valve ��002
13.3 External tightness ��004
13.4 Electric safety requirements (explosion protection) ��005
13.4.1. Kinds of protection means ��006
13.4.2. European and Asia/Pacific Approvals ��006
13.4.2.1 Approval Agencies ��006
13.4.2.2 CENELEC Approvals ��006
13.4.2.3 Types of Protection ��006
13.4.2.4 ATEX 100 - EC Directive 94/9 ��007
13.4.2.5 CENELEC member countries: ��008
13.4.2.6 European directives and standards ��008
13.4.2.7 European Directive 94/9/EC (ATEX 100a) ��008
13.4.2.8 International Electrotechnical Commission IEC �� 011
13.4.2.9 CENELEC �� 011
13.4.3. North American Approvals �� 011
13.4.3.1 National Electrical Code (NEC) �� 011
13.4.3.2 The National Electrical Manufacturers Association (NEMA) �� 013
13.4.3.3 NEMA Enclosure Rating �� 013
13.4.3.4 General Locations �� 014
13.4.3.5 Hazardous (Classified) Locations �� 016
13.4.3.6 What is IEC 60529 and what does it cover? �� 016
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Table of contents
13.4.3.7 What is not covered by IEC 60529? �� 016
13.4.3.8 What does "degree of protection" mean in IEC 60529? �� 017
13.4.3.9 CSA Enclosure Ratings �� 017
13.4.3.10 Entity Concept �� 017
13.4.3.11 CSA System Parameter Concept �� 018
13.4.3.12 Loop Schematic (Control Drawing) �� 018
13.5 Comparison of Protection Techniques ��019
13.5.1. Degrees of protection provided by enclosures (IP Code) �� 021
13.5.1.1 North American Ex Marking and Area Classification ��023
13.5.2. European and Rest of World Hazardous Area Standards and Approvals
��023
13.5.2.1 ATmospheric EXplosibles (ATEX) ��023
13.5.2.2 ATEX Directive 94/9/EC Article 100a ��024
13.5.2.3 Assessment of Explosion Risks ��024
13.5.2.4 Explosive Atmospheres Warning Sign ��025
13.5.3. Classes, Divisions, Groups ��026
13.5.3.1 Electrical equipment ��026
13.5.3.2 Non-electrical equipment ��026
13.5.3.3 Equipment category and Equipment protection level (EPL) ��027
13.5.3.4 Zones and Divisions ��027
13.5.3.5 Groups ��028
13.5.3.6 Temperature classification ��028
13.5.4. Types of protection for electrical apparatus in hazardous areas ��029
13.5.4.1 Types of protection for non-electrical equipment in gas and dust

atmospheres ��030
13.5.4.2 Types of protection for electrical apparatus in areas with
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Table of contents
combustible dust �� 031

13.6 Safety accountability of pressure containing components ��031
13.7 Pressure Equipment Directive (PED) 97/23/EC ��033
13.7.1. Glossary of Pressure Equipment Directive (PED) ��034
13.7.2. Classification of Control Valves ��037
13.7.2.1 Conformity Assessment Diagrams ��038
13.7.2.2 The conformity assessment modules ��046
13.7.2.3 Specific Pressure Equipment Requirements (PED Annex I 4.3)

��047
13.7.3. CE MARKING ��048
13.8 Declaration of Conformity ��050
13.9 Requirements in case of critical fluids / procedures ��054
13.9.1. Control valves for oxygen ��054
13.9.2. Industrial gases with increased requirements ��055
13.9.2.1 Industrial gases ��055
13.9.2.2 Purity level 1 (high purity) ��056
13.9.2.3 Purity level 2 (pure) ��056
13.9.2.4 Purity level 3 (pure) ��056
13.9.3. Control valves in plants for production of chlorine ��056
13.9.3.1 Versions for chlorine service ��057
13.9.4. Control valves for sour gas applications ��057
13.9.5. Customer- or fluid-specific demands on control valves ��058
13.10 Safety-instrumented Systems according to IEC 61508 and IEC 61511 ��062
13.10.1. Introduction ��062
13.10.2. Safety system requirements ��063
13.10.2.1 Analytical activities ��064
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13.10.2.2 Activities for implementation ��064
13.10.2.3 Process operation ��064
13.10.3. Risk analysis and risk reduction ��065
13.10.4. Sources of failure and their avoidance ��068
13.10.5. Systematic failure ��069
13.10.6. Random failure �� 070
13.10.7. Hardware fault tolerance (IEC 61508, Part 2) �� 072
13.10.8. Further terminology �� 073
13.10.8.1 Device type A and device type B �� 073
13.10.9. Useful lifetime �� 074
13.10.10. Assessment by an independent person �� 074
13.10.11. Requirements for selection of instruments �� 075
13.10.11.1 Prior use �� 076
13.10.12. Devices of the SAMSON GROUP �� 076
13.10.13. Further information �� 077
13.10.14. Summary concerning SIL ��077
13.10.15. References �� 078
13.11 Manual of Functional safety (WA 236 EN) ��079
13.11.1. Scope �� 079
13.11.2. Validity of this manual �� 079
13.11.3. Intended use of this manual ��080
13.11.4. General aspects of functional safety ��080
13.11.4.1 Standards, terms and abbreviations ��080
13.11.4.2 Determining the safety integrity level ��082
13.11.4.3 Hardware fault tolerance ��083
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13.12 Intended use of control valves in safety-instrumented systems ��084
13.12.1. General control valve requirements ��086
13.12.2. Globe valve requirements ��087
13.12.3. Ball valve requirements ��089
13.12.4. Butterfly valve requirements ��090
13.12.5. Rotary plug valve requirements ��091
13.12.6. Proof tests and service life ��092
13.13 Installation, piping and wiring ��092
13.13.1. Mechanical and pneumatic installation ��092
13.13.2. Electrical installation ��093
13.13.3. Installation of control valves ��094
13.14 Applicable device documentation ��095
13.15 Appendix 1 – Manufacturer‘s declarations ��095
13.16 Manufacturer's Declaration ��095
13.17 Appendix 2 − Example of a checklist for a final element ��096
13.18 MANUAL - Competence in Functional Safety (WA 239 EN) ��098
13.18.1. Application notes for safety-instrumented systems ��098
13.18.2. Validity and intended use of this manual ��098
13.18.3. Structure of this manual ��098
13.18.4. Requirements stipulated in VDI 2180 ��099
13.18.5. Terms and abbreviations ��099
13.18.6. The complete safety-instrumented system ��100
13.18.7. Instrumented valves �� 102
13.18.8. SAMSON GROUP products for safety-instrumented systems �� 104
13.18.9. Automated testing �� 107
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13.18.9.1 Final elements �� 107
13.18.10. Test methods �� 109
13.18.10.1 Online testing: partial stroke test �� 109
13.18.10.2 Further test options �� 112
13.18.11. Integration into the process control system �� 113
13.18.11.1 Architecture �� 113
13.18.11.2 Documentation of partial stroke testing �� 115
13.18.11.3 Continuous workflow �� 115
13.18.12. Effects on risk analysis �� 118
13.18.12.1 Systematic faults �� 118
13.18.12.2 Spurious faults �� 118
13.18.12.3 Fault tolerance measures �� 121
13.18.13. Life cycle �� 121
13.18.14. Bibliography �� 122
14. Specification and selection of control valves

14.1 Purchaser / end user information ��001
14.2 SAMSON Group valve sizing and valve selection philosophy ��004
14.2.1. Purchaser / end user information �� 012
14.2.1.1 Multiple pressure characteristic system: pressure versus flow �� 012
14.2.2. Severe service data management, support and customer care philosophy
�� 014
14.2.2.1 Corrosion & Erosion �� 014
14.2.2.2 Abrasion �� 015
14.2.2.3 The specified pipe size is too small and do not take critical
velocities into account. �� 015
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14.2.2.4 Customer care, help and troubleshooting philosophies �� 017
14.3 Flow direction ��017
14.4 Selection of the required nominal pressure range ��019
14.5 Selection of the required valve size ��020
14.5.1. Calculated Cv (Kv) and rated Cv (Kv). ��020
14.5.2. Flow velocity ��020
14.6 Control valve sizing and selection with SVS and SVSS valve sizing software.
��021
14.6.1. Sizing and selection of valve series and types �� 024
14.6.2. Special calculations ��024
14.6.2.1 Calculation of closing and opening times ��024
14.6.3. Graphic support with diagrams ��024
14.6.4. Valve characteristic: �� 024
14.6.5. Pressure-temperature diagram ��026
14.6.6. Property calculation ��026
14.6.7. Other features of the SAMSON Valve Sizing Program include: ��027
14.7 Connection with the pipeline ��028
14.8 Selection of the correct valve bonnet ��029
14.9 Selection of suitable materials ��030
14.10 Internal sealing and leak proofing to the outside ��030
14.11 Specification of the valve actuator ��031
14.12 Specification of control valve accessories ��032
14.13 Hazardous locations (zone) and type of protection ��033
14.14 Ambient temperatures and specific climates ��034
14.15 Types of protection against climatic influences ��034
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14.16 Housings for electrical devices in accordance with NEMA ��036
14.16.1. Definitions pertaining to non-hazardous locations ��036
14.16.2. Definitions pertaining to hazardous (classified)locations �� 037
14.17 Piping (tubing) and fittings ��039
14.18 The selection of a suitable control valve ��040
14.19 Is control valve selection a magic? ��040
15. Interface to a control systems

15.1 Fieldbuses ��001
15.1.1. Fieldbus technology saves time and reduces costs ��001
15.2 Network topologies ��002
15.2.1. Mesh topology ��002
15.2.2. Line or Bus technology ��002
15.2.3. Tree topology ��002
15.2.4. Ring topology ��002
15.2.5. Star topology ��003
15.2.6. Contents of the CENELEC fieldbus standards ��004
15.2.7. Structure of IEC 61158, fieldbus for industrial control systems ��006
15.2.8. Profiles and protocols according to IEC 61158 and IEC 61784 ��006
15.2.8.1 Data Link Layer (DLL) ��007
15.2.8.2 Application Layer (AL) ��007
15.2.8.3 Physical Layer (PhL) ��007
15.2.8.4 Communications Stack ��007
15.2.8.5 Network Management (NM) ��007
15.2.8.6 Link ��007
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15.2.8.7 Link Active Scheduler (LAS) ��007
15.2.8.8 Foundation™ Fieldbus (FF) consists of three profiles: ��008
15.2.8.9 The Danish Fieldbus P-Net: ��008
15.2.8.10 Swiftnet ��008
15.2.8.11 The PROFIBUS solution ��008
15.2.9. Therefore, there exist now six different device profiles in IEC 61158 ��008
15.2.10. Summary ��008
15.3 HART® Communications ��009
15.3.1. What is HART®? �� 010
15.3.2. HART networks �� 012
15.3.3. Universal Handheld Communicators �� 016
15.3.4. Wire Lengths & Capacitance �� 016
15.3.5. What is in the HART® Data? �� 018
15.3.6. Integration of HART Data �� 019
15.3.7. Open Architecture Applications ��020
15.3.7.1 HART Within a PROFIBUS Network ��020
15.3.7.2 HART/DDE Server ��020
15.3.8. WirelessHART Communication �� 021
15.4 PROFIBUS and PROFINET ��022
15.4.1. What is PROFIBUS? ��023
15.4.2. The ISO/OSI reference model ��026
15.4.3. The PROFIBUS „Tool Box“ ��029
15.4.4. Transmission Technologies ��030
15.4.5. Communication Protocols �� 031
15.4.6. PROFIBUS Transmission Technology ��032
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15.4.7. PROFINET ��034
15.4.7.1 Passive and active PROFINET ��035
15.4.8. PI International ��036
15.4.9. One single cable ��037
15.4.10. Global access ��037
15.4.11. Wireless communication ��037
15.4.12. Maintenance and diagnostics ��037
15.4.13. Maximum performance ��037
15.4.14. Scalable communication ��037
15.4.15. IT compatibility of communication ��038
15.4.16. Communication in the automation engineering ��038
15.4.17. PROFIBUS DP/PA Link ��038
15.4.18. PROFIBUS-DP ��039
15.4.19. PROFIBUS PA ��039
15.4.20. PROFIBUS Device Certification ��040
15.4.21. Product Guide of PROFIBUS & PROFINET �� 041
15.4.22. Twisted shielded pair cable ��043
15.4.23. PROFIBUS DP ASICs ��043
15.4.24. Key Functions of PROFINET ��044
15.4.25. Requirements for a Modern Diagnostic Concept ��045
15.4.26. Enhanced Information Access ��046
15.5 Fieldbus FOUNDATION™ ��047
15.5.1. What is FOUNDATION™ (FF) technology? ��048
15.5.1.1 What is FOUNDATION H1? ��048
15.5.1.2 How is FOUNDATION H1 unique? ��048
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15.5.1.3 Is FOUNDATION H1 easier to use than traditional technology? 049
15.5.1.4 What are the benefits of H1? ��049
15.5.2. FOUNDATION HSE �� 051
15.5.2.1 A key technology for enterprise integration �� 051
15.5.2.2 Designed to support mission-critical applications ��052
15.5.2.3 Function Block Model (FFB) ��052
15.5.2.4 Blocks enable fieldbus device functionality ��052
15.5.2.5 Electronic Device Description Language (EDDL) ��052
15.5.2.6 Safety Instrumented Functions (SIF) ��053
15.6 SAMSON smart Positioner Series 373X-X ��055
15.6.1. SAMSON smart positioners ��056
15.6.2. SAMSON smart explosion–proof Positioner (EEx d) Type 3731-X ��057
15.6.3. Overview of Electropneumatic Positioners Type 373X-X ��058
15.6.3.1 Features of smart Positioners Series 3730-X and 3731-X ��065
15.6.3.2 SAMSON PROFIBUS Certificate ��066
15.6.4. Fieldbus Device Registration SAMSON Type 3730-5 and 3731-5 ��067
15.7 Optimized device integration Center ��068
15.8 Electrical connections ��070
15.8.1. Electrical connections of electro pneumatic Positioner Type 3730-0 �� 071
15.8.2. Electrical connections of Positioner Type 3730-1 �� 071
15.8.3. Switching amplifiers �� 072
15.8.4. Electrical connections of electro pneumatic Positioner Type 3730-2 �� 073
15.8.5. Electrical connections of HART® Positioner Type 3730-3 �� 073
15.8.6. Electrical connections of PROFIBUS Positioner Type 3730-4 �� 074
15.8.7. Electrical connections of Foundation™ fieldbus Positioner Type 3730-5
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�� 074
15.8.8. Electrical connections HART® Ex-d Positioner Type 3731-3 �� 075
15.8.9. Electrical connections Foundation™ Ex-d Positioner Type 3731-5 �� 077
15.8.10. Summary of Positioners 3730-X and 3731-X �� 078
15.9 Universal Mounting ��079
15.10 Pneumatic actuators ��081
15.10.1. Examples of assembly to valves of the competition ��083
15.10.2. Example of special assemblies ��084
15.11 TROVIS-VIEW Type 6661 ��087
15.11.1. What is TROVIS-VIEW ? ��088
15.11.2. TROVIS-VIEW - One interface to serve all needs ��090
15.11.3. Software TROVIS-VIEW use for ��090
15.11.4. Basic program (Shell) ��090
15.11.5. Global design ��091
15.11.6. Communication with SSP ��092
15.11.7. Multilingual ��094
15.11.8. TROVIS-VIEW V3.60 is free of charge ��096
15.11.9. System requirements ��097
15.11.10. Software TROVIS-VIEW use for digital operating SAMSON-devices ��097
15.11.11. Accessories ��098
15.11.12. Online operation (direct data transmission) ��098
15.11.13. Offline operation (indirect data transmission) ��098
15.11.14. Summary TROVIS-VIEW ��100
15.12 SAMSON EXPERT ��101
15.12.1. EXPERT, EXPERT+ and Partial Stroke Test (PST) �� 103
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15.12.2. Application type: Control valve or on/off valve �� 105
15.12.3. EXPERT Valve Diagnostics with TROVIS-VIEW3 Operator Interface ��106
15.12.4. Special mode for control valve and on-off valve �� 107
15.13 PACTware™ ��108
15.13.1. What is PACTware™ �� 109
15.13.2. How works FDT? �� 110
15.13.3. For which fieldbusses is PACTware suitable? ��111
15.13.4. Plug & Play in automation �� 112
15.13.5. Device Type Manager (DTM) �� 112
15.13.6. PACTware is universally usable. �� 114
15.13.7. FDT/DTM or EDDL for Asset Management using Foundation Fieldbus

technology. �� 114
15.13.8. EDDL™ - The key to interoperability �� 115
15.13.9. EDDL : How Does It Work? �� 115
15.13.10. What is in the EDD? �� 116
15.13.11. Proven, available technology �� 116
15.13.12. Who is behind PACTware? �� 117
15.13.13. Summary �� 118
15.14 Positioner series 373X-X integration into control systems or tools ��123
16. Quality assurance of industrial control valves

16.1 SAMSON Quality Manual - Process overview ��001
16.2 Inspection and routine testing (according to IEC 60534-4:2006) ��002
16.2.1. Shell hydrostatic test ��003
16.2.1.1 Test pressure-group acc. DIN EN ��004
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16.2.1.2 Test pressure (bar) acc. NSI / ASME, ISA-75.19.01-2001 for valves
��005
16.2.1.3 Test pressure for JIS valves (JIS B 2201-1984) ��005
16.2.1.4 Test pressure-qroup acc. ANSI / ASME ��006
16.2.1.5 Exclusions from hydrostatic test ��007
16.2.2. Seat leakage test �� 011
16.2.3. Packing test �� 011
16.2.4. Test procedure for valves with spring-opposed actuators �� 011
16.2.4.1 Dead band �� 011
16.2.4.2 Dead band tests �� 013
16.2.4.3 Test procedure for valves with double-acting actuators �� 013
16.2.5. Additional examinations and manufacturing inspection �� 014
16.3 Material certificates according to EN 10204: 1991/A1:1995 ��015
16.3.1. Material certificates according to EN 10204: 1991/A1:1995 �� 015
16.3.2. Non-specific tests are the following �� 016
16.3.3. Specific tests are the following �� 016
16.3.4. How long can acceptance test certificates 3.1A and 3.1C to
DIN EN 10204:1995 still be ordered? �� 017
16.4 Inspection certificates to new DIN EN 10204:2005 ��017
16.4.1. Summary of inspection documents according to DIN EN 10204:2005 �� 019
16.4.2. Clare definition for “Manufacturer” and “Intermediary �� 019
16.4.2.1 Transmission of inspection documents by an intermediary ��020
16.4.3. Example: Test and inspection plan for Valve Series 3240 ��022
16.4.4. Example: Test and inspection plan for Valve Series 3250 ��023
16.5 To comply with requirements of PED ��024
16.5.1. Conformity with Annex I Section 4.3 of PED ��024
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16.6 Legal consequences ��025
17. Valves used in petroleum refining processes

17.1 Introduction ��001
17.1.1. Where Oil- and Gas is coming from? ��001
17.1.1.1 Plankton, source of oil and gas ��001
17.1.2. Oil field units ��003
17.1.2.1 Oil-well derrick ��004
17.1.2.2 Platforms for offshore drillings ��005
17.1.2.3 Strategic Assets in the Offshore Value Chain ��006
17.1.3. What is crude oil (Petroleum)? ��007
17.1.4. Oil: Proved reserves at end 2009 �� 010
17.1.5. Petroleum chemistry �� 014
17.1.6. API gravity ��020
17.1.7. Classification of gases ��022
17.2 Upstream, Middlestream, and Downstream process areas ��023
17.2.1. Specific control valve challenges in the oil & gas production, petroleum
transportation and storage are: ��026
17.3 Refineries ��027
17.3.1. Fuel refineries and petrochemical refineries. ��027
17.4 Refinery processes ��028
17.4.1. Complexity of a Refinery ��030
17.4.1.1 Factors deciding the complexity of a refinery ��030
17.4.2. Typical Refinery Production ��030
17.4.3. Overview of Petroleum Refining Processes �� 031
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17.4.4. Separation processes ��034
17.4.4.1 Separation of oil and gas ��035
17.4.4.2 Separation of oil and salt water ��035
17.4.4.3 Stripping/desorption ��036
17.4.4.4 Crude distillation ��036
17.4.4.5 Atmospheric distillation ��038
17.4.4.6 Vacuum distillation ��040
17.4.5. Conversion processes (Cracking) �� 041
17.4.5.1 Thermal cracking �� 041
17.4.5.2 Visbreaking (viscosity breaking) �� 041
17.4.5.3 Coking ��042
17.4.5.4 Catalytic cracking ��043
17.4.5.5 Hydrocracking ��045
17.4.6. Reforming ��046
17.4.7. Upgrading �� 047
17.4.7.1 Desulfurization �� 047
17.4.7.2 Claus unit ��047
17.4.7.3 Hydrotreating ��048
17.4.7.4 Mercaptan conversion ��050
17.4.7.5 Amine treatment of sour gas ��050
17.5 Auxiliary facilities ��051
17.5.1. Hydrogen production �� 051
17.5.2. Desulfurization and hydrogenation �� 051
17.5.3. Steam reforming ��052
17.5.4. CO conversion ��052
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Table of contents
17.5.5. Hydrogen purification ��052
17.5.6. Steam systems ��052
17.5.7. Condensate treatment unit ��052
17.5.8. Under firing of furnaces ��052
17.5.9. Turbo compressors ��053
17.5.10. Anti-surge control valve application ��054
17.5.10.1 Control valves with extremely fast and precise positioning control
loop ��055
17.5.10.2 Example: Anti-Surge application ��056
17.6 Control valves in petroleum refining processes ��057
17.6.1. Introduction ��057
17.6.2. General requirements and standards ��057
17.6.3. Valve styles ��060
17.6.4. Seat and plug ��061
17.6.5. Noise-abating trims and parts ��062
17.6.5.1 SAMSON’s gas and vapor handling ��062
17.6.5.2 SAMSON’s handling with liquids ��063
17.6.6. Pressure balance design ��064
17.6.7. Plug sealing and leakage rate ��065
17.6.8. Packing ��065
17.6.9. Bonnet stuffing box design ��066
17.6.10. SAMSON’s Bellows seal: Sealed for life ��067
17.6.10.1 SAMSON bellows seal design ��068
17.6.11. Materials ��069
17.6.12. Actuators �� 070
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17.6.13. Rotary plug valves design features �� 071
17.6.14. Typical application fields and installations: �� 071
17.6.15. Typically other manufacturer rotary plug valve design �� 073
17.6.16. Standard butterfly valves design features �� 074
17.6.16.1 High performance triple eccentric butterfly valve design features

�� 075
17.6.17. Standard ball valves design features �� 078
17.6.18. Valve accessories �� 079
17.6.18.1 Positioners �� 079
17.6.18.2 Limit switches ��080
17.6.18.3 Position transmitter/potentiometer ��080
17.6.18.4 Solenoid valves ��080
17.6.18.5 Lock-up valves ��080
17.6.18.6 Pneumatic remote adjuster �� 081
17.6.18.7 Supply pressure regulators �� 081
17.6.18.8 Pneumatic boosters �� 081
17.6.18.9 Reversing Amplifier �� 081
17.7 Examples of refining processes ��082
17.7.1. Crude oil treatment ��083
17.7.2. Atmospheric crude distillation �� 103
17.7.3. Vacuum distillation �� 173
17.7.4. Catalytic reformer (CCR – Continuous Catalytic Reformer) �� 179
17.7.5. Hydrocracker ��184
17.7.6. Visbreaker �� 189
17.7.7. Claus unit �� 195
Page LI

Table of contents
17.7.8. Catalytic hydrotreating (hydrogenation) ��202
17.7.9. Steam reformer �� 207
17.7.10. PSA plant �� 214
17.7.11. Amine treatment of sour gas ��221
17.7.12. Steam system ��227
17.7.13. Condensate treatment ��232
17.7.14. Underfiring furnaces ��237
17.7.15. Turbo compressor �� 241
17.8 Petrochemical refinery ��245
17.8.1. Petrochemistry ��246
17.8.2. Basic Petrochemical Flow Scheme ��246
17.8.2.1 Petrochemicals �� 247
17.8.2.2 What is a Steam Cracker? ��248
17.9 Natural Gas ��251
17.9.1. The gas trade grows increasingly significantly �� 252
17.9.2. Projected annual growth in demand 2000 to 2020 ��253
17.10 Liquefied Natural Gas or Liquefied Petroleum Gas - a crucial difference?

��255
17.10.1. Liquefied petroleum gas (LPG), ��255
17.10.2. Liquefied natural gas (LNG) ��255
17.10.3. What is LNG? ��255
17.10.4. Where does LNG come from? ��255
17.10.5. What countries import LNG? ��255
17.10.6. Natural Gas Composition ��256
17.10.7. Is LNG flammable? ��256
Page LII

Table of contents
17.10.8. Is LNG explosive? ��256
17.10.9. Gas processing �� 257
17.11 NG production block scheme ��258
17.11.1. How is LNG used? ��259
17.11.2. How is LNG transported? �� 261
17.11.3. How is LNG stored? ��262
17.11.4. How is natural gas (NG) stored? ��262
17.11.5. Why use LNG? ��262
17.11.6. This list of natural gas fields includes major fields. ��263
17.11.7. LNG Exporters ��264
17.11.8. LNG Importers ��265
17.12 Recovering oil or gas at great depths ��266
17.12.1. Floating storage and off-loading (FSO) or Floating production storage and
offloading (FPSO) ��266
17.12.2. Gas Carrier Classification with Cargo Capacity to 100,000 m3 ��267
17.12.3. FPSO “AOKA MIZU” ��268
17.13 Floating LNG Production and Regasification ��269
17.13.1. The Floating and Regasification Unit (FRU) Concept ��269
17.13.2. The Floating Storage and Regasification Unit (FSRU) Concept �� 270
17.14 Refinery nomenclature and other terms ��274
18. Calculation examples

18.1 Calculation and selection of a control valve for liquids ��001
18.1.1. .Solution ��001
18.1.1.1 Calculation of Cv-value, selection of valve characteristic and

nominal size. ��001
Page LIII

Table of contents
18.1.1.2 Cavitation and reliability check and prediction of the noise level to
be expected ��002
18.1.1.3 Valve type and trim material selection for SAMSON globe valve.
��004
18.1.1.4 Cavitation sound means: ��004
18.1.1.5 Critical cavitation for globe valves is defined in SAMSON sizing:

��005
18.1.1.6 Valve selection flowchart ��007
18.1.1.7 Actuator calculation �� 010
18.1.1.8 Example 18.1 Comparison with SAMSON SIZING �� 012
18.2 Calculation and selection of a control valve for steam ��016
18.2.1. Solution �� 016
18.2.1.1 Calculation of the flow coefficient (Cv-value). selection of the valve

characteristic and nominal size. �� 016
18.2.1.2 Calculation of sound pressure level at normal flow �� 018
18.2.1.3 Summary: ��020
18.2.1.4 Comparison with SAMSON SIZING ��022
18.2.1.5 Calculation and selection of a suitable actuator ��026
18.2.1.6 Comparison with SAMSON SIZING ��028
18.2.1.7 SAMSON SPECIALIST SVSS ��030
18.2.1.8 Material selection ��032
18.3 Calculation of flow coefficient for non-turbulent flow conditions ��032
18.3.1. Solution ��035
18.3.1.1 Comparison with SAMSON SIZING �� 037
18.4 Examples to the actual International Standard ��041
18.5 Calculation of stroking times (integrated in SAMSON Valve Sizing) ��046
18.5.1. Pipeline influence ��048
Page LIV

Table of contents
Page LV


Control Valves Handbook

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CONTROL VALVES

I hope you enjoy reading or consulting this handbook.

Dr. Jörg Kiesbauer

Copyright © 2010 SAMSON AG · All rights reserved.

The manufacturer’s instructions on the use of any commercial product must be

SAMSON AG cannot be held liable for any misuse, misappropriation, or violations of

1.1.2. Scope of topics �����������������������������������������������������������������������������������������002

1.1.3. How to use this book? �������������������������������������������������������������������������������003

1.1.4. Structure and sequence ����������������������������������������������������������������������������003

1.2 SAMSON your Partner for Automation and Control ��������������������������������������004

1.2.1. An Innovative Leader in Global Markets ��������������������������������������������������005

1.2.2. Market segments ��������������������������������������������������������������������������������������006

1.3 Research and Development at SAMSON �������������������������������������������������������007

1.3.1. Optimized device integration ��������������������������������������������������������������������� 012

1.4 Production at SAMSON ������������������������������������������������������������������������������������015

1.5 Quality assurance at SAMSON ������������������������������������������������������������������������018

1.6 Logistic center and dispatch department ������������������������������������������������������020

1.7.1. The associated companies ������������������������������������������������������������������������ 021

1.8 SAMSON’s Project execution �������������������������������������������������������������������������030

1.9 Extract of reference installations ��������������������������������������������������������������������031

1.10 Subsidiaries and Engineer and Sales Offices of SAMSON GROUP ����������044

1.10.1. Extract of the subsidiaries �����������������������������������������������������������������������045

2. Terms and definitions

2.2.1. Sectional drawings of Type 3241-7 ����������������������������������������������������������� 013

SAMSON AG · MESS- UND REGELTECHNIK · Weismüllerstraße 3 · 60314 Frankfurt am Main · Germany

2.2.3. Three-way Valve �������������������������������������������������������������������������������������� 017

2.2.3.1 Mixing service ����������������������������������������������������������������������������� 017

2.2.3.2 Flow-diverting service ����������������������������������������������������������������� 018

2.2.4. Metal bellows seal and insulating section ������������������������������������������������� 019

2.2.5. Valve bodies and styles ����������������������������������������������������������������������������020

2.2.6. Valve and component terminology �����������������������������������������������������������025

2.3 Used symbols and units ���������������������������������������������������������������������������������032

2.4 SI quantities and units of measurement ��������������������������������������������������������044

2.5 Units derived from the SI system ��������������������������������������������������������������������045

2.7 Conversion Tables (Examples of SI coherent derived units) �����������������������052

2.7.1. Length SI derived units ������������������������������������������������������������������������������052

2.7.2. Area SI derived units ��������������������������������������������������������������������������������055

2.7.3. Volume SI derived units ����������������������������������������������������������������������������057

2.8 Angle SI derived units ��������������������������������������������������������������������������������������061

2.8.2. Weight and Mass SI derived units ������������������������������������������������������������062

2.8.3. The World Clock - Time Zones �����������������������������������������������������������������064

2.8.4. Speed or velocity SI derived units ������������������������������������������������������������067

2.8.5. Acceleration SI derived units ��������������������������������������������������������������������068

2.8.6. Moment of Inertia SI derived units ������������������������������������������������������������069

2.8.7. Density SI derived units ����������������������������������������������������������������������������069

2.8.8. Gage pressure, atmospheric pressure and absolute pressure ����������������� 071

2.8.9. Pressure, stress SI derived units �������������������������������������������������������������� 072

2.8.10. Force SI derived units ����������������������������������������������������������������������������� 075

SAMSON AG · MESS- UND REGELTECHNIK · Weismüllerstraße 3 · 60314 Frankfurt am Main · Germany

2.8.11. Torque SI derived units ��������������������������������������������������������������������������� 076

2.8.12. Energy SI derived units ���������������������������������������������������������������������������077

2.8.13. Conversion table for Power units in relation to SI units ��������������������������� 079

2.8.14. Dynamic viscosity SI derived units ���������������������������������������������������������� 081

2.8.15. Kinematic viscosity SI derived units �������������������������������������������������������� 081

2.9 Flow SI derived units ����������������������������������������������������������������������������������������082

2.9.1. Temperature SI derived units ��������������������������������������������������������������������083

2.10 List the mathematical symbols ��������������������������������������������������������������������084

2.10.1. Greek alphabet in roman and italic type ��������������������������������������������������086

2.11 Terminology and Symbols in Control Engineering �������������������������������������087

2.11.1. A pre-standard for the uniform representation of requirements of the

2.12.1. Personal Protective Equipment (PPE) �����������������������������������������������������094

2.12.2. Mandatory signs �������������������������������������������������������������������������������������096

2.12.4. Fire protection symbols and additional symbols ��������������������������������������097

2.13.1. Why is GHS needed? ������������������������������������������������������������������������������098

1.1.2. Scope of topics ��002

1.1.3. How to use this book? ��003

1.1.4. Structure and sequence ��003

1.2 SAMSON your Partner for Automation and Control ��004

1.2.1. An Innovative Leader in Global Markets ��005

1.2.2. Market segments ��006

1.3 Research and Development at SAMSON ��007

1.3.1. Optimized device integration �� 012

1.4 Production at SAMSON ��015

1.5 Quality assurance at SAMSON ��018

1.6 Logistic center and dispatch department ��020

1.7.1. The associated companies �� 021

1.8 SAMSON’s Project execution ��030

1.9 Extract of reference installations ��031

1.10 Subsidiaries and Engineer and Sales Offices of SAMSON GROUP ��044

1.10.1. Extract of the subsidiaries ��045

2.2.1. Sectional drawings of Type 3241-7 �� 013

2.2.3. Three-way Valve �� 017

2.2.3.1 Mixing service �� 017

2.2.3.2 Flow-diverting service �� 018

2.2.4. Metal bellows seal and insulating section �� 019

2.2.5. Valve bodies and styles ��020

2.2.6. Valve and component terminology ��025

2.3 Used symbols and units ��032

2.4 SI quantities and units of measurement ��044

2.5 Units derived from the SI system ��045

2.7 Conversion Tables (Examples of SI coherent derived units) ��052

2.7.1. Length SI derived units ��052

2.7.2. Area SI derived units ��055

2.7.3. Volume SI derived units ��057

2.8 Angle SI derived units ��061

2.8.2. Weight and Mass SI derived units ��062

2.8.3. The World Clock - Time Zones ��064

2.8.4. Speed or velocity SI derived units ��067

2.8.5. Acceleration SI derived units ��068

2.8.6. Moment of Inertia SI derived units ��069

2.8.7. Density SI derived units ��069

2.8.8. Gage pressure, atmospheric pressure and absolute pressure �� 071

2.8.9. Pressure, stress SI derived units �� 072

2.8.10. Force SI derived units �� 075

2.8.11. Torque SI derived units �� 076

2.8.12. Energy SI derived units ��077

2.8.13. Conversion table for Power units in relation to SI units �� 079

2.8.14. Dynamic viscosity SI derived units �� 081

2.8.15. Kinematic viscosity SI derived units �� 081

2.9 Flow SI derived units ��082

2.9.1. Temperature SI derived units ��083

2.10 List the mathematical symbols ��084

2.10.1. Greek alphabet in roman and italic type ��086

2.11 Terminology and Symbols in Control Engineering ��087

2.12.1. Personal Protective Equipment (PPE) ��094

2.12.2. Mandatory signs ��096

2.12.4. Fire protection symbols and additional symbols ��097

2.13.1. Why is GHS needed? ��098

2.13.2. Hazard Classification ��098

2.13.3. GHS implementation by country (67 countries listed) ��099

2.14 Identification of pipelines according to the fluid conveyed. ��108

3.3 Continuity equation ��002

3.4 Energy equation (Bernoulli equation) ��003

3.4.1. Static pressure energy px ��004

3.4.2. Potential energy (energy of the situation or height) ��004

3.4.3. Kinetic energy or speed energy ��004

3.5 Flow out of an open vessel ��006

3.7.1. Vertical push against a wall ��009

3.9 Reynolds law of similarity ��014

3.11 Flow in piping systems ��016

3.12 Friction losses at laminar flow ��017

3.13 Friction losses at turbulent flow ��018

3.14 Special resistors in pipes ��019

3.15 Valves as pipe resistors ��022

3.16 Throttling of incompressible fluids ��023

3.17 Energetic consideration of the throttling process ��025

3.18 Operation of pumps in a pipe line system ��026

3.19 Pump and System Curves ��033

3.19.1. Parallel pumping ��033

3.19.2. Series Pumping ��035

4.4 Phase diagrams of ideal gases ��005

4.5 Energy and enthalpy ��007

4.6 Real gases and vapors ��008

4.7 Flow through nozzles ��009