CONTROL VALVE SELECTION & SIZING

By Keps

Source:
 (Fisher Controls International LLC & Emerson Automation Solutions, 2017)
 (FISHER CONTROL VALVE SOURCEBOOK, n.d.)
 (Pipe Drafting and Design, Roy A. Parisher & Robert A. Rhe.)

Table of Content
 Control Valve
 Control Valve Selection
1. Body and Movement
2. Flow Characteristic
3. Actuator Type
4. Positioner Type
 Control Valve Sizing
1. Liquid Valve Sizing
2. Gas Valve Sizing
 Control Valve Severe Service
1. Cavitation and Flashing

CONTROL VALVE
• Control valve is a vital component used to regulate the flow of liquids or gases

• It operates by adjusting the passage of the fluid or gasses through a pipeline or

conduit in response to electronic or pneumatic signals from a controller

• This dynamic control allows the valve to maintain precise levels of pressure,
temperature, or flow rate within a system, ensuring that the process operates
efficiently and safely.

CONTROL VALVE SELECTION

1. Body and Movement
 Sliding Stem • Rotary (Quarter Turn)

Uses a circular or rotational motion (90°) to control fluid flow. Ball

valves and butterfly valves are common examples of rotary movement
Operated by using a linear sliding motion of a valve stem to control the control valves
opening and closing of the valve. • Compact design and Cost effective
• Often used in applications where precise flow control is • Lower friction, but limited flow range
needed • valves can provide quick quarter-turn operation, but low
• Suitable for a wide range of flow rates and high pressure. precise control
• Limited speed operating with higher frictio
 2. Flow Characteristic

`
 Linear: Flow is directly proportional to valve
opening, offering steady control

 Equal-Percentage: Equal increment of valve travel

produce equal percentage changes in the existing
flow. Ideal for varying flow needs

 Quick Opening: Rapidly allows maximum flow with

small initial movement. Suitable for fast on/off
control.

 Liquid Level System

Best Inherent
Control Valve Pressure Drop
Characteristic
Constant P Linear
Decreasing P with increasing load, P at maximum load > 20% of minimum load P Linear
Decreasing P with increasing load, P at maximum load < 20% of minimum load P Equal-percentage
Increasing P with increasing load, P at maximum load < 200% of minimum load P Linear
Increasing P with increasing load, P at maximum load > 200% of minimum load P Quick Opening

 Pressure Control System

Best Inherent
Application
Characteristic
Liquid Process Equal-Percentage
Gas Process, Large Volume (Process has a receiver, Distribution System or
Transmission Line Exceeding 100 ft. of Nominal Pipe Volume), Decreasing P with Linear
Increasing Load, P at Maximum Load > 20% of Minimum Load P
Gas Process, Large Volume, Decreasing P with Increasing Load, P at Maximum Equal-Percentage
Load < 20% of Minimum Load P
Gas Process, Small Volume, Less than 10 ft. of Pipe between Control Valve and Load Equal-Percentage
Valve

 Flow Control Processes

Application Best Inherent Characteristic
Small Range of Flow but
Flow Measurement Signal Location of Control Valve in
Wide Range of Flow Set Point Large P Change at Valve
to Controller Relation to Measuring Element
with Increasing Load
Proportional to Flow In Series Linear Equal-Percentage
In Bypass* Linear Equal-Percentage
Proportional to Flow In Series Linear Equal-Percentage
Squared
In Bypass* Equal-Percentage Equal-Percentage
*When control valve closes, flow rate increases in measuring element.

Flow characteristics of a control valve can be adjusted by customizing various components beyond just the cage.
The trim, including the plug, stem, and seat ring, can be tailored to achieve specific flow profiles such as linear, equal
percentage, or quick opening. Modifying the plug shape, for instance, can significantly alter the valve's response to changes
in flow. Here is example of the cage trim selection for each flow characteristic:
3. Actuator Type
 Diaphragm Actuator  Piston Actuator

The piston moves within a cylinder,

When the control pressure transferring force to the valve
changes, the stem. These actuators are available
diaphragm flexes, in both pneumatic and hydraulic
causing the actuator's versions and are suitable for a wide
stem to move and range of valve sizes and thrust
adjust the valve's requirements.
position.
Advantages:
o Generating substantial thrust,
making them suitable for larger valves
o Stability and have a precise control
Advantages:
o Fail-Safe Operation: Can be configured with a spring
o Simple design and easy to maintain.
return mechanism. the spring will drive the valve to a
o Fail-Safe Operation: Can be configured to fail-open or
pre-defined fail-safe position (open or close).
fail-close upon loss of air supply, ensuring safety in
critical applications.
Disadvantages:
o Diaphragm actuators offer excellent leakage
o More complex than diaphragm actuators, potentially
protection
increasing maintenance requirements and more
Disadvantages: expensive.
o Limited to relatively low force output compared to o Have a slower response time, especially in
piston actuators, which can be a drawback in high- pneumatic configurations without a fast-acting control
pressure applications. system.
o Typically has a shorter stroke length compared to
piston actuators, limiting its use in applications that
require longer strokes.  Electro-Hydrolic
Motor with a hydraulic pump to generate
hydraulic pressure, which then acts on a
 Electric Motor piston to move the valve stem. Provides
Uses an electric motor to drive a high force output with precise control.
Advantages:
gear mechanism that moves the
valve stem. The motor's rotation is
o Capable of providing very high
force and torque, suitable for
converted into linear or rotary large and high-pressure valves.
motion to operate the valve. o Excellent throttling ability and
Advantages: fast stroking speed.
o Provides precise control over valve position, ideal for o Fail-Safe Operation: Can be
applications requiring fine adjustments. designed to fail-safe in a specific
o Does not need pneumatic or hydraulic supply, position using spring
simplifying installation (Compactness). mechanisms or hydraulic accumulators. In case of
Disadvantages: power failure, these mechanisms can drive the valve
o Fail-Safe Operation: Typically does not have an to a predefined position (open, close, or a specific
inherent fail-safe position. Requires additional intermediate position).
components like spring-return mechanisms or battery Disadvantages:
backup systems to ensure the valve moves to a safe o Highly complex, integrating electrical, hydraulic, and
position during a power failure. mechanical components, which can increase
o Slower in response compared to pneumatic actuators, maintenance requirements and more expensive.
making it less suitable for fast-acting applications.

4. Positioner Type
 Pneumatic Positioner (P/P)

It operates by using pneumatic pressure signals for both input and output. Pressure is
typically modulated between 3 to 15 psig to move the valve from 0 to 100% position.

o Accurate and consistent positioning of control valves, also offer stable and
reliable control, minimizing disturbances.
o They may not be as versatile when working with different types of control
signals.
  Electric to Pneumatic Positioner (I/P)
An I/P positioner uses a converter module that converts a 4 to 20 mA current
input to a proportional pressure output to move the valve 0 – 100 % positions.

o Can work with various control signal sources, offering versatility in

different control system configurations.
o Have slightly lower accuracy compared to dedicated pneumatic
positioners.

VALVE SELECTION PROCESS

Determine Service Condition Calculate Preliminary CV Required

o (P1, ΔP, Q, T1, Fluid Properties, Allowable
Select Trim Type
o Check Noice and Cavitation levels.
o If no noise or
noice, ect).
cavitation indication,
o Select appropiriate ANSI pressure class
required for valve body and trim. choose standard
Select Valve Body and Trim Size trim
o Select valve body and trim size with o If aerodynamic or
require CV. liquid noise is high,
o Note travel, trim group, and shutoff choose severe
Select Trim Material service trim type
options.
Select trim materials for the application; make
sure trim selected is available in the trim group
for the valve size selected
Option
Consider option on shutoff, stem packing, ect.

CONTROL VALVE SIZING

The goal is to ensure optimal performance in regulating the flow of fluids within a system.
Proper sizing involves considering factors like flow rates, pressure drop, fluid properties, and
desired control accuracy.
By choosing the right size, the control valve can effectively manage the fluid flow, maintain
desired process conditions, and contribute to efficient and safe operation.
To perform control valve sizing, numerous calculations are required as outlined in the
referenced book mentioned earlier. However, to save time, I typically use applications like
InstruCalc. Alternatively, sizing can also be done using software provided by vendors or
companies that offer specialized valve sizing tools.

InstruCalc is a software application designed to assist engineers with various calculations related to instrumentation and control.
It simplifies complex processes like control valve sizing, flow calculations, and pressure drop estimations by providing a user-
friendly interface and built-in formulas. This tool significantly reduces the time and effort needed for manual calculations,
ensuring accurate and reliable results for instrumentation tasks in industrial settings.
Abbreviations and Terminology
Symbol Symbol
Cv Valve sizing coefficient P1 Upstream absolute static pressure
d Nominal valve size P2 Downstream absolute static
pressure

D Internal diameter of the piping Pc Absolute thermodynamic critical

pressure
Fd Valve style modifier, Pv Vapor pressure absolute of liquid at
dimensionless inlet temperature
FF Liquid critical pressure ratio factor, P Pressure drop (P1-P2) across the
dimensionless valve
Fk Ratio of specific heats factor, Pmax(L) Maximum allowable liquid sizing
dimensionless pressure drop
FL Rated liquid pressure recovery Pmax(LP) Maximum allowable sizing pressure
factor, dimensionless drop with attached fittings
FLP Combined liquid pressure recovery q Volume rate of flow
factor and piping geometry factor of
valve with attached fittings (when
there are no attached fittings, FLP
equals FL),
dimensionless
FP Piping geometry factor, qmax Maximum flow rate (choked flow
dimensionless conditions) at given upstream
conditions
Gf Liquid specific gravity (ratio of T1 Absolute upstream temperature
density of liquid at flowing (degree K or degree R)
temperature to density of water at
60°F), dimensionless
Gg Gas specific gravity (ratio of density w Mass rate of flow
of flowing gas to density of air with
both at standard conditions(1), i.e.,
ratio of
molecular weight of gas to
molecular weight of air),
dimensionless
k Ratio of specific heats, x Ratio of pressure drop to upstream
dimensionless absolute static pressure (P/P1),
dimensionless
K Head loss coefficient of a device, xT Rated pressure drop ratio factor,
dimensionless dimensionless
M Molecular weight, dimensionless Y Expansion factor (ratio of flow
coefficient for a gas to that for a
liquid at the same Reynolds
number), dimensionless
N Numerical constant Z Compressibility factor,
dimensionless
1 Specific weight at inlet conditions
 Kinematic viscosity, centistokes
1. Standard conditions are defined as 60°F (15.5°C) and 14.7 psia (101.3kPa).

Severe service is defined if one or more of the following conditions apply:

𝑃1 −𝑃2
 Liquid Service : Cavitation factor, 𝐾𝑐 = > 0.7
𝑃1 −𝑃𝑉

𝑃1 −𝑃2
 Gas service : 𝑐𝑟𝑖𝑡𝑖𝑐𝑎𝑙 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒 𝑑𝑟𝑜𝑝 = > 0.5
𝑃1

 Gas service: 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒 𝑑𝑟𝑜𝑝 > 50 𝑏𝑎𝑟

 Liquid service: 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒 𝑑𝑟𝑜𝑝 > 30 𝑏𝑎𝑟

 Noise ≤ 85 dBa
THE SIZING RESULT USING INSTRUCALC

 CONTROL VALVE SEVERE SERVICE

The vena contracta is the point where the flow area of a liquid is at its
minimum, located downstream of the restriction.

The exact position varies with pressure conditions and the type of
restriction. At this point, the pressure, known as the vena contracta
Vena Contracta pressure (𝑃𝑣𝑐), reaches its minimum. After this, the pressure recovers to
the downstream pressure, which is lower than the upstream pressure due
to energy conversion into heat.

Noise in control valves is caused by high flow velocities and pressure

drops, leading to turbulence, cavitation, and aerodynamic noise, which
can cause mechanical vibrations, damage, and unsafe conditions.

High noise levels can increase the risk of flashing and cavitation, potentially damaging the valve and piping system. Regulations
like OSHA and ISO 9612 require noise levels below 85 dBa to protect workers' hearing and health. Exposure to noise above
this limit can lead to hearing loss and stress, so maintaining noise levels within this range ensures a safer work environment.

1. Cavitation 2. Flashing

Cavitation occurs when Flashing occurs when

pressure at valve outlet recover pressure at valve outlet
above the liquid’s vapor remains below the
pressure with high recovery liquid’s vapor pressure
factor, and the bubbles will (low recovery factor),
collapse or implode. and the bubbles remain in
the flow stream.

These collapsing bubbles

This can affect the valve's ability to
can actually hurt the valve's
control the flow properly and might
insides over time, like small
even wear down the valve's parts
water hammers, and make
over time.
the valve less effective or
being damaged.