CONTROL VALVE SIZING USING DWSIM 08 January 2023

By Viraj Desai, Process Engineer

CONTROL VALVE SIZING USING DWSIM:

A FREE AND OPEN-SOURCE CHEMICAL PROCESS SIMULATOR

BY
VIRAJ DESAI, PROCESS ENGINEER
EMAIL: VIRAJ DESAI

LEVEL: INTERMEDIATE
VERSION: 0.00
JANUARY 2023

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 CONTROL VALVE SIZING USING DWSIM 08 January 2023
By Viraj Desai, Process Engineer

PREFACE

The manual “Control Valve Sizing Using DWSIM” presents a set of “Control valve Sizing for
incompressible fluid” exercise using a free and open-source chemical process simulator “DWSIM”
and can be utilized to establish process simulation laboratory as part of undergraduate chemical
engineering degree or in allied degree curriculum. The problem statements are of intermediate
level.

Prerequisite

• Must know about DWSIM UI/UX.

• Flow sheeting in DWSIM
• Selection of Thermodynamic Packages.
• Manipulating variables
• Line Hydraulics
• Basic Modules

Thanks

Viraj Desai

P.E. O&G

Disclaimer

All the exercises are strictly restricted to learning only and not meant to be used in real world
application.

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 CONTROL VALVE SIZING USING DWSIM 08 January 2023
By Viraj Desai, Process Engineer

PROCESS SIMULATION USING DWSIM: A FREE AND OPEN-SOURCE CHEMICAL

PROCESS SIMULATOR

PREAMBLE

DWSIM is an open-source CAPE-OPEN compliant chemical process simulator. It features a Graphical

User Interface (GUI), advanced thermodynamics calculations, reactions support and petroleum
characterization / hypothetical component generation tools. DWSIM can simulate steady-state,
vapor–liquid, vapor–liquid-liquid, solid–liquid and aqueous electrolyte equilibrium processes and has
built-in thermodynamic models and unit operations (https://en.wikipedia.org/wiki/DWSIM ). It is
available for Windows, Linux and Mac OS.

The objective of the course is to create awareness of the open-source process simulator “DWSIM”
among prospective graduates and practicing process engineers. The course will cover Intermediate
aspects of create flow sheet in DWSIM and simulation of simple Pressure changing module like pipe
segment, Compressor, etc.

Target Audience

• Junior Interns in Process Firms

• III / Final year B. Tech. Chemical Engineering students
• M. Tech. Chemical Engineering students
• Practicing Process Engineers

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 CONTROL VALVE SIZING USING DWSIM 08 January 2023
By Viraj Desai, Process Engineer

Table of Contents

1 Background ..................................................................................................................................... 6
1.1 Overview of Control Valve Sizing ............................................................................................ 6
1.2 Critical Sizing Elements ........................................................................................................... 6
2 Control Valve Sizing......................................................................................................................... 7
3 Cross-Checking in KORF hydraulics ............................................................................................... 18
4 Manual calculation in SMath Studio ............................................................................................. 20
5 References .................................................................................................................................... 21

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 CONTROL VALVE SIZING USING DWSIM 08 January 2023
By Viraj Desai, Process Engineer

List of Figures

Figure 1 Problem Statement ................................................................................................................... 7

Figure 2 Suction header stream specs .................................................................................................... 8
Figure 3 Pipe segment............................................................................................................................. 8
Figure 4 Upstream Inlet Line Specs ......................................................................................................... 9
Figure 5 Adding specs for hydraulic profile |Valve Inlet Pipe |. ........................................................... 10
Figure 6 Elevation vs horizontal distance profile for Valve inlet pipe .................................................. 11
Figure 7 Pipe segment of Valve Outlet Specs ....................................................................................... 12
Figure 8 Adding specs for hydraulic profile |Valve Outlet Pipe | ......................................................... 13
Figure 9 Elevation vs horizontal distance profile for Compressor outlet pipe ..................................... 14
Figure 10 Valve Specs............................................................................................................................ 15
Figure 11 Flow Sheet ............................................................................................................................. 16
Figure 12 Coefficient of discharge ........................................................................................................ 17
Figure 13 Control valve Coefficient of discharge calculation in KORF .................................................. 18

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 Background 08 January 2023
By Viraj Desai, Process Engineer

1 BACKGROUND

1.1 OVERVIEW OF CONTROL VALVE SIZING

Standardization activities for control valve sizing can be traced back to the early 1960s when a trade
association, the Fluids Control Institute, published sizing equations for use with both compressible
and incompressible fluids. The range of service conditions that could be accommodated accurately
by these equations was quite narrow, and the standard did not achieve a high degree of acceptance.
In 1967, the ISA established a committee to develop and publish standard equations. The efforts of
this committee culminated in a valve sizing procedure that has achieved the status of American
National Standard. Later, a committee of the International Electrotechnical Commission (IEC) used
the ISA works as a basis to formulate international standards for sizing control valves. The ANSI/ISA-
75.01.01 and IEC 60534-2-1 valve sizing standards have been harmonized, so either standard may be
used.

1.2 CRITICAL SIZING ELEMENTS

It is important to provide the following information in order to size a control valve properly:

• Physical details (pipe size, pressure class, trim type)

• Process conditions (upstream pressure, downstream pressure, temperature, noise limit)
• Fluid properties (flow rate, density)

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 Control Valve Sizing 08 January 2023
By Viraj Desai, Process Engineer

2 CONTROL VALVE SIZING

Objective

Find the coefficient of discharge for the given control valve in the problem statement.

Data

Figure 1 Problem Statement

DWSIM Blocks Used

• Pipe segment
• Material Stream
• Control valve

Procedure

1. Start a new DWSIM Simulation (DWSIM VER 8.3 - CLASSIC UI). Click on “New steady state
Simulation” as a template for new simulation
2. The simulation configuration window will be opened. It shows a specification page. Add
components required to solve the problem statement. In the present case, add water.
Ensure the component is added from the same property database. For instance, in this case,
both components are added from “ChemSep” database.
3. Specify the thermodynamic package as Steam Tables (IAPWS-IF97) (1).
4. Customize the system of units for the simulation and click “Next”.

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 Control Valve Sizing 08 January 2023
By Viraj Desai, Process Engineer

5. The flow sheeting section of simulation window will be opened. First, let provide suction
header, valve inlet, valve outlet and discharge header streams for the unit operation to be
performed.
6. On clicking the “Suction header” stream, general information about the stream will be
displayed on the left side of screen. Specify the feed compositions, temperature, and
pressure for the inlet streams. Once credentials are specified for the Suction header
streams, the color of stream turns blue.

Figure 2 Suction header stream specs

7. Below the Unit Operation tab on left, locate the pipe segment block. Drag and drop into the
flow sheet. Rename it as “Upstream line”.

Figure 3 Pipe segment

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 Control Valve Sizing 08 January 2023
By Viraj Desai, Process Engineer

8. Under specification for pipe segment add the data as follows.

Figure 4 Upstream Inlet Line Specs

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 Control Valve Sizing 08 January 2023
By Viraj Desai, Process Engineer

9. Click on the hydraulic profile as shown in the image

Figure 5 Adding specs for hydraulic profile |Valve Inlet Pipe |.

Segment 1

Type Straight Tube

Quantity 1

Increments 5

Material Stainless Steel

Rugosity (m) 4,5E-05

Therm. Conduct. (W/[m.K]) T-Dep

Length (m) 100

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 Control Valve Sizing 08 January 2023
By Viraj Desai, Process Engineer

Elevation (m) 0

Ext. diameter (mm) 219.075

Int. diameter (mm) 202.717

10. Click on “View” in hydraulic profile tab to see layout of pipe network

Figure 6 Elevation vs horizontal distance profile for Valve inlet pipe

11. Once all segments are added with the data provided as reference in the table above click on

green tick mark to apply changes

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 Control Valve Sizing 08 January 2023
By Viraj Desai, Process Engineer

12. Similarly add a pipe segment name it as “Valve outlet line” And add the following specs.

Figure 7 Pipe segment of Valve Outlet Specs

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 Control Valve Sizing 08 January 2023
By Viraj Desai, Process Engineer

Figure 8 Adding specs for hydraulic profile |Valve Outlet Pipe |

Segment 1

Type Straight Tube

Quantity 1

Increments 5

Material Stainless Steel

Rugosity (m) 4,5E-05

Therm. Conduct. (W/[m.K]) T-Dep

Length (m) 100

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 Control Valve Sizing 08 January 2023
By Viraj Desai, Process Engineer

Elevation (m) 0

Ext. diameter (mm) 219.075

Int. diameter (mm) 202.717

Figure 9 Elevation vs horizontal distance profile for Compressor outlet pipe

13. Once all segments are added with the data provided as reference in the table above click on

green tick mark to apply changes

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 Control Valve Sizing 08 January 2023
By Viraj Desai, Process Engineer

14. Add a valve from the pressure changes ribbon and connect the “Upstream line” and
“Downstream line”. And rename it as FCV-1. And add the following specs

Figure 10 Valve Specs

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 Control Valve Sizing 08 January 2023
By Viraj Desai, Process Engineer

15. Once done click on calculation type drop down and select Liquid Service Kv/Kc deprecated
and select Cv. Then again select outlet pressure from drop down of calculation type

16. Run the simulation by pressing “Solve flow sheet” button on the top corner of the screen

Figure 11 Flow Sheet

17. Click on FCV-1 and click on calculate to get Cv of valve.

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 Control Valve Sizing 08 January 2023
By Viraj Desai, Process Engineer

18. Click on report generation to get control valve characteristics

Figure 12 Coefficient of discharge

Valve Valve Discharge Suction

inlet outlet Header Header
Temperature (C) 121.112 121.35 121.35 121.111
Pressure (bar) 21.6641 7.23237 7.1988 21.6977
Mass Flow (kg/h) 106958 106958 106958 106958
Molar Flow (kmol/h) 5937.06 5937.06 5937.06 5937.06
Volumetric Flow (m3/h) 113.4 113.51 113.511 113.4
Density (Mixture) (kg/m3) 943.189 942.273 942.271 943.191
Molecular Weight (Mixture) 18.0153 18.0153 18.0153 18.0153
(kg/kmol)
Specific Enthalpy (Mixture) (kJ/kg) 509.884 509.884 509.884 509.884
Specific Entropy (Mixture) 1.53801 1.54189 1.5419 1.538
(kJ/[kg.K])
Molar Enthalpy (Mixture) (kJ/kmol) 9185.71 9185.71 9185.71 9185.71
Molar Entropy (Mixture) 27.7077 27.7776 27.7778 27.7075
(kJ/[kmol.K])
Thermal Conductivity (Mixture) 0.684457 0.683619 0.683617 0.684459
(W/[m.K])

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 Cross-Checking in KORF hydraulics 08 January 2023
By Viraj Desai, Process Engineer

3 CROSS-CHECKING IN KORF HYDRAULICS

Figure 13 Control valve Coefficient of discharge calculation in KORF

29 Control Valve
Sizing for Incompressible Fluid Korf Results.pdf

Control Valve Calculations Korf Results

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Cross-Checking in KORF hydraulics 08 January 2023
By Viraj Desai, Process Engineer

UPSTREAM LINE PROFILE DATA

Length Inclination Pressure Temperature Liquid Vapor Heat Liquid Flow Overall HTC h (Internal) k/L (Wall) k/L (Insulation) h (External) External
(m) (degrees) (bar) (C) Velocity Velocity (kW) Holdup Regime (W/[m2.K]) (W/[m2.K]) (W/[m2.K]) (W/[m2.K]) (W/[m2.K]) Temperature (C)
(m/s) (m/s)
0 0 21.6977 121.111 0.975977 0 0 1 Liquid 0 0 0 0 0 25
Only
20 0 21.691 121.111 0.975978 0 0 1 Liquid 0 0 0 0 0 25
Only
40 0 21.6842 121.111 0.975978 0 0 1 Liquid 0 0 0 0 0 25
Only
60 0 21.6775 121.111 0.975979 0 0 1 Liquid 0 0 0 0 0 25
Only
80 0 21.6708 121.112 0.975979 0 0 1 Liquid 0 0 0 0 0 25
Only
100 0 21.6641 121.112 0.97598 0 0 1 - 0 0 0 0 0 25
DOWNSTREAM LINE PROFILE DATA
Length Inclination Pressure Temperature Liquid Vapor Heat Liquid Flow Overall HTC h (Internal) k/L (Wall) k/L (Insulation) h (External) External
(m) (degrees) (bar) (C) Velocity Velocity (kW) Holdup Regime (W/[m2.K]) (W/[m2.K]) (W/[m2.K]) (W/[m2.K]) (W/[m2.K]) Temperature (C)
(m/s) (m/s)
0 0 7.23237 121.35 0.976928 0 0 1 Liquid 0 0 0 0 0 25
Only
20 0 7.22565 121.35 0.976929 0 0 1 Liquid 0 0 0 0 0 25
Only
40 0 7.21894 121.35 0.976929 0 0 1 Liquid 0 0 0 0 0 25
Only
60 0 7.21223 121.35 0.97693 0 0 1 Liquid 0 0 0 0 0 25
Only
80 0 7.20551 121.35 0.97693 0 0 1 Liquid 0 0 0 0 0 25
Only
100 0 7.1988 121.35 0.97693 0 0 1 - 0 0 0 0 0 25

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 Manual calculation in SMath Studio 08 January 2023
By Viraj Desai, Process Engineer

4 MANUAL CALCULATION IN SMATH STUDIO

29 Control Valve
Sizing for Incompressible Fluid Smath Studio Results.pdf

Smath Studio Manual Calculations

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References 08 January 2023
By Viraj Desai, Process Engineer

5 REFERENCES
1. Control Valve Sizing Emerson

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