Control vale sizing

 Ball valve
The ball valve opening can be positioned in the fully open or fully closed position but must
not be used to throttle flow as any abrasive wear to the ball will cause leakage when the valve
is closed.
Ball valves are considered high recovery valves, having a low pressure drop and relatively
high flow capacity.
Best Suited Control: Quick opening, linear Recommended
Uses: Fully open/closed, limited throttling
Higher temperature fluids
Applications: Ball valves are excellent in chemical applications, including the most
challenging services (e.g. dry chlorine, hydrofluoric acid, oxygen).
Advantages:
 Low cost
 High flow capacity
 High pressure/temperature capabilities
 Low leakage and maintenance
Disadvantages:
 Limited throttling characteristics
 Prone to cavitation

 Butterfly Valves:
The butterfly valves are used for limited throttling where a tight shut off is not required.
When fully open, the butterfly creates little turbulence or resistance to flow.
Best Suited Control: Linear, Equal percentage

Recommended Uses:
 Fully open/closed or throttling services
 Frequent operation
 Minimal fluid trapping in line
 Applications where small pressure drop is desired
Applications:
 Most economical for large lines in chemical services, water treatment, and fire
protection systems. General sizes available are 2" to 48", although sizes up to 96" are
available from certain manufacturers.
 Due to the valve design, incorporating a small face-to-face dimension and lower
weight than most valve types, the butterfly valve is an economical choice for larger
line sizes (i.e. 8" and above).
Advantages:
 Low cost and maintenance
 High capacity
 Good flow control
 Low pressure drops
Disadvantages:
 High torque required for control
 Prone to cavitation at lower flows
 Lack of cleanliness and inability to handle slurry applications.

 Globe Valves:
Best Suited Control: Linear and Equal percentage
Recommended Uses:
Applications requiring:
 Precise flow regulation
 Frequent and wide throttling operation
 Suited to very high pressure drops
Applications:
 Suitable for most liquids, vapors, gases, corrosive substances
 General sizes available are 1/2" to 8".
 Pressure limitations are relatively high, ranging from 1480 to 1500 psi, dependent on
materials of construction, size and temperature.
 Minimum and maximum temperatures are also very broad ranging from -425°F to
1100°F, depending again on the materials of construction.

Advantages:
  Efficient and precise throttling
 Accurate flow control
Disadvantages:
 Low recovery and relatively low coefficient of flow (Cv).
 High pressure drops, higher pump capacity and system wear
 More expensive than other valves
 The sealing device is a plug that offers limited shut-off capabilities, not always
meeting bubble tight requirements.

 Gate Valves:
Best Suited Control: Quick Opening
Recommended Uses:
 Fully open/closed, non-throttling
 Infrequent operation
 Minimal fluid trapping in line
Applications:
 Suitable for oil, gas, air, heavy liquids, steam, non-condensing gases, abrasive and
corrosive liquids
 Sizes available range from standard cast configurations as small as 2" to special
fabricated valves exceeding 100".
Advantages:
 High capacity
 Tight shutoff
 Low cost
 Little resistance to flow
 Ability to cut through slurries, scale and surface build-ups
 Provide unobstructed flow paths that not only provide high flow capacity (Cv), but
even allows slurry, large objects, rocks and items routinely found in mining processes
to safely pass through the valve.

Disadvantages:
 Poor control
  Cavitate at low pressure drops
 Cannot be used for throttling
 Relatively low-pressure limitation - general pressure limitations are 150 psi at
maximum.

ACTUATORS
A valve actuator is a device that produces force to open or close the valve utilizing a power
source. This source of power can be manual (hand, gear, chain-wheel, lever, etc.) or can be
electric, hydraulic or pneumatic.

 Basic actuators turn valves to either fully opened or fully closed positions. But
modern actuators have much more advanced capabilities.
 They not only act as devices for opening and closing valves but also provide
intermediate position with high degree of accuracy.
Type of Actuators
pneumatic and electric actuators.
Pneumatic actuators utilize an air signal from an external control device to create a control
action via a solenoid.
Electric actuators are motor driven devices that utilize an electrical input signal to generate
a motor shaft rotation. This rotation is, in turn, translated by the unit’s linkage into a linear
motion, which drives the valve stem and plug assembly for flow modulation.
VALVE POSITIONER Valve positioner is a control device designed to impart sensitivity to
the valve and to ensure accurate positioning as dictated by a control signal.
It receives an electronic or pneumatic signal from a controller and compares that signal to the
actuator’s position.
If the signal and the actuator position differ, the positioner sends the necessary power—
usually through compressed air—to move the actuator until the correct position is reached.
A positioner may be used as a signal amplifier or booster.
It accepts a low-pressure air control signal and, by using its own higher-pressure input,
multiplies this to provide a higher-pressure output air signal to the actuator diaphragm, if
required, to ensure that the valve reaches the desired position.

CONTROLLING THE VALVE

A control loop consists of a sensing element, a controller and the final control element - the
valve and its actuator.

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CONTROL VALVE FUNDAMENTALS

Control Valve Capacity - Cv:

For sizing a control valve, we are interested in knowing how much flow we can get through
the valve for any given opening of the valve and for any given pressure differential.
The relationship between pressure drops and flow rate through a valve is conveniently
expressed by a flow coefficient (Cv).
Flow coefficient (Cv):
 Number of gallons per minute (gpm)
 60°F that will pass through a full open valve(100%open)
 pressure drop of 1 psi
Control valve which has a Cv of 12 means
 fully open position
 12gpm of water
 1 psi pressure drop
 60°F

For incompressible fluids like water

 Cv = Valve flow coefficient

 Q = Fluid flow, US GPM (also given by Area of pipe x mean velocity)
 S = Specific gravity of fluid relative to water @ 60ºF
 ∆P = Pressure drops (P1 – P2) across the control valve at maximum flow, psi
Greater the pressure drop, higher will be the flow rate. Pressure drops across a valve is
highly influenced by the area, shape, path and roughness of the valve.

Example:
Assume there is a 15-psi pressure drop across a control valve when the valve is wide open
with a flow rate of 150 gpm of water through the valve. The specific gravity of water is one.
The valve coefficient can be calculated as: Cv = 150 * (1 / 15) ½ = 38.72 gpm

Once we know the valve coefficient, we can then calculate the pressure drop across the valve
for a given flow rate, OR a flow rate for a given pressure drops.
For example, determine the pressure drop across the above valve if the flow rate increases to
200 gpm.
∆P = (Q / Cv)2 x S = (200 / 38.72) 2 x 1 = 26.68 psi
In practice, once you know the design flow rate and the desired pressure drop, one can
calculate the required valve Cv and select a proper valve from the manufacturers'
literature.

Note:
The Kv value is the metric equivalent of Cv expressed in in m3/hr with 1 bar pressure
drop at a temperature between 5 °C and 40 °C.

Cv = 1.15 x Kv

As the pressure drop across the valve is increased, it reaches a point where the increase in
flow rate is less than expected.
This continues until no additional flow can be passed through the valve regardless of the
increase in pressure drop. This condition is known as choked flow.
Choked flow (otherwise known as critical flow) takes place:
 When an increase in pressure drops across the valve no longer has any effect on
the flow rate through the valve.
 When the velocity of the gas or vapor reaches sonic velocity (Mach 1) at the vena
contracta.
At vena contra,
1. Velocity reduces and recovers to same level
2. Pressure reduces and wont recovers to same level (will be a pressure drop)

1. Choked Flow in Liquids (Cavitation & Flashing)

 Causes:
 Happens when the pressure drops below the vapor pressure of the liquid, leading
to vapor bubble formation.
 This can occur due to excessive pressure drop across the valve.

 Effects:
Cavitation:
 Vapor bubbles form and then collapse violently when pressure recovers, causing
erosion and damage to the valve and downstream piping.
 Creates noise, vibration, and efficiency loss.
Flashing:
 If downstream pressure remains below vapor pressure, the liquid stays in a
vaporized state.
 This leads to erosion and damage due to high-velocity two-phase flow.

 Solution:
 Use cavitation-resistant valves (e.g., trim designs that manage pressure drop
gradually).
Note: If pressure at vena contra drops below the vapour pressure, flasing happens (due to
increased fluid velocity at this point.
 high recovery valve (like a ball valve, butterfly valve, or plug valve): pressure
drops sharply at the vena contracta but then recovers quickly after the valve.

 low recovery valve (like a globe valve or cage-guided valve): In contrast, low
recovery valves allow pressure to drop more gradually, keeping the vena
contracta pressure higher and avoiding cavitation

2. Choked Flow in Gases & Steam (Sonic Flow)

 Causes:
 Occurs when the flow velocity reaches the speed of sound (Mach 1) at the vena
contracta (smallest flow area in the valve).
 Further increasing upstream pressure won’t increase flow rate because the gas
molecules can’t move faster than the speed of sound.
 This happens when the pressure ratio (P1/P2) exceeds the critical pressure ratio:
(depends on gas properties, typically ~0.5 to 0.6 for air).
 Effects:
 Flow becomes independent of downstream pressure → No increase in flow even
if P2 decreases.
 Increased noise and vibration → Can damage valve internals.
 Shock waves in extreme cases → Structural damage in high-pressure systems.
  Solution:
 Use pressure staging (two or more control valves in series).
 Use special trim designs to handle high-pressure drops without choking.

Avoid Cavitation:
1. Control valve with proper trim
2. Use a valve with a low recovery coefficient
 Valve recovery refers to the pressure recovery from the low pressure at vena
contracta to the valve outlet.
 Safe to say that a low recovery valve will resist causing cavitation more than a
high recovery type.
3. Increase the downstream pressure by installing a flow restrictor if possible or
reducing the pipe size of a short piece downstream.

CONTROL VALVE CHARACTERISTICS

 Linear
 Equal percentage
 Quick opening

General rules:
How do you decide which valve control to use?
Here are some rules of thumb:
Linear Characteristics:
 Used in liquid level or flow loops.
 Used in systems where the pressure drops across the valve is expected to remain
constant (i.e. steady state systems).
 Used when the pressure drops across the valve is a large proportion of the total
pressure drop.
Equal Percentage Characteristics:
 Used in processes where large changes in pressure drop are expected.
 Used in Gas lines/Two phase lines.
 Used in processes where a small percentage of the total pressure drop is permitted by
the valve.
 Used in temperature and pressure control loops.
Quick Opening Characteristics:
 Used for frequent on-off service.
 Used for processes where "instantly" large flow is needed (i.e. safety systems or
cooling water systems).

 If the control valve is undersized (Cv - too small), the required flow rate will not be
achieved even when the valve is fully opened.
 If a selected control valve is too large (Cv – too large), it will not provide the desired
control and may cause the system to hunt or cycle.
Sizing for liquid services:
Using bernoulli, liquid flows through orifice, square of the fluid velocity is directlty
proportional to the pressure differential across the orifice and inversily proportional to the
specific gravity of the liquid.
Greater the pressure differential, higher the velocity
Greater the density, Lower the velocity

To calculate expected Cv, above equation is used for a valve controlling or other liquids that
behave like water.
Viscosity corrections:
Viscous condition can result significant sizing errors in using the basic Cv equation. Cv
equation values are based on test data using water as flow medium.
If Viscosity corrections are relatively small, we can use Cv values.
Thus, Cv value can be changed to,

Cvr = Fv Cv
Graph of Reynolds number vs viscosity correction factor Fv is used to determine the
correction factor needed.
Actual required Cv (Cvr) is found by above equation
Note: From manufacturer publised liquid capacity information, select a valve having Cv
equal to or higher than the required coefficient (Cvr) found by the equation above.

Predicting flow rate

Select required liquid sizing coefficient (Cvr) from manufacturer published liquid sizing
coefficient (Cv) for the style and size being considered. Maximum flow rate in gallon per
minute (assuming no viscosity correction)

Calculate the predicted flow rate by considering viscosity correction factor

Predicting Pressure drop

Select required liquid sizing coefficient (Cvr) from manufacturer published liquid sizing
coefficient (Cv) for the style and size being considered. Calculate the sizing coefficient (Cvc)

Calculating the predicted flow rate

Use this equation to determine the maximum allowable pressure drop that is effective in
producing flow.

After calculating ∆Pallow, substitute it into basic liquid sizing equation to determine Q
and Cv. If actual ∆P is less than ∆Pallow, then actual ∆P should be taken

However, in high recovery valves such as ball or butterfly valves, significant cavitation can
occur at pressure drop below that which produces choked flow.
So, although ∆Pallow and Km are useful in predicting choked flow capacity, a separate
cavitation index Kc is needed to determine the pressure drop at which cavitaion damage will
begin in high recovery valves.
The equation expressed as

∆Pc = Kc (P1 -Pv)

Control valve sizing procedure:
1. Specify the variables required to size the valve
 Process fluid
 Desired design
 Appropriate service conditions


2. Determine the equation constant from the table

 Use N1, if sizing the valve for a flow rate in volumetric unit (GPM or N3/hr)
Use N6, if sizing the valve for a flow rate in mass unit (Pound/hr or Kg/hr)

3. Determine Fp, the piping geometry factor

 Fp, is correction factor that accounts for pressure losses due to piping fittings such as
reducers, elbows, or tees that might be attached directly to inlet and outlet connection
of control valve
 If such fiitings are attached the the contol valve, Fp, factor muct be considered.
 If no fittings, Fp = 1.

4. Determine Qmax (maximum flow rate at given upstream condition) or ∆Pmax (allowable
sizing pressure drop)
 The maximum or limiting flow rate Qmax commonly called choked flow.
 In liquids, choking happens when static pressure within valve falls below vapour
pressure of the liquid.
 ∆Pmax (allowable sizing pressure drop) is calculated and compared with the actual ∆P
(actual pressure drop). Lesser of these two values is taken for sizing.
 If recognized that choked flow won’t develop, no need to calculate ∆Pmax
FL: Rated iquid pressure recovery factor
FF: Liquid critical pressure ratio factor
Once ∆Pmax is calculated, compares with ∆P (actual pressure drop), low value is taken for
sizing.
If ∆Pmax is less than ∆P (actual pressure drop): Choked flow condition exist

5. solve for required Cv using the appropriate equation:

If ∆P (P1 -P2) > ∆Pmix, choked condition, ∆P replace with ∆P mix value.

6. Select the valve size using the appropriate flow coefficient table and the calculated Cv
valve.