1_

Control Valve Sizing

--.

1991, ALL RIGHTS

RESERVED

BULLETIN

NO. SM-8

TABLE

OF CONTENTS

Valve Sizing ................................................. Page 2 Valve Sizing Equations ................................. Page 3 Viscosity Correction ..................................... Page 4 Small Flow Valve Sizing .............................. Page 4 Cv Table Series 24000 Lfttle Scatty ............. Page 5 Cv Table Series 24000s Stainless Steel......Pag e6 Cv Table Series 21000 Elastomer Lined.. .. ..Pag e 7 Cv Table Series 25000 LO-T Rotary.. ......... .Page 7 Cv Series 26000 Corrosion Resistant .......... Page 7 Cv Series 86000 Corrosion Resistant.. ........ Page 7 CV Series 41000 Rotoglobe ......................... Page 8 Incipient Cavitation ....................................... Page 8 Damage Cavitation ................................... ..Pag e 8 Avoidance of Cavitation ............................... Page 9 Aerodynamic Noise Estrmate ..................... Page 10 Graphical Method .................................... Page 11

UMANN

ASSOC,

LTD.

1.94

35 Mirona Road Portsmouth, NM. 03801 Phone: (603) 436-2044 Fax: (603) 436-4901

VALVE

SIZING

Selecting the right size control valve is very important. For example, a valve that is too small might waste pump horsepower. On the other hand, a valve too large may not be able to handle reduced flows. Most valve manufacturers publish a so-called rated C, Factor for each size and type of control valve. This simply indicates the maximum flow in gallons per minute of water which would pass through the valve at a pressure drop of 1 psi. To select the proper size valve. however, requires full knowledge of actual flowing conditions and method of calculating the required C,. Valve sizing equations as standardized by the ISA (Standard S75.01) have vastly improved in accuracy primarily through the addition of a Pressure Recovery Factor F, and a Piping Geometry Factor F,. both of which were originated by Hans D. Baumann of our company in 1962 and 1968. respectively (formerly known as C, and R). The following equations have been adapted from the ISA S75.01 Standard to allow for practical everyday use without significant sacrifice in accuracy. For more comprehensive sizing use our computer software VS3. Proceed by calculating the required valve C, from given flow data, having prior determined the flow is critical or sub-critical. whether

%d

Next, select a valve size (or trim size) from the capacity tables shown on pages 5. 6. and 7. Note, tf

a Lo-T valve is installed between reducers, multiply rated C, by F,. The other valve types, having
relatively lower capacity, do not require this correction. However, if the required maximum C, is more than 80% of the rated C,, or C, x F,, for a given valve size, then choose a next larger valve or trim. For example, for a given flow rate of 5670 Ibs/hr sat. steam at 250 psia inlet and 150 psia outlet, a C, of 13.5 is calculated. A l-1 14 Little Scatty with V-port trim has a maximum C, of 15. However, 13.5 is more than 80% of 15. therefore, a l-l /2 size valve with a rated C, of 23 is recommended. Also. do not select a conventional globe valve or metal seated butterfly valve if the minimum required C, falls at less than 5% of valve travel (see C, Tables). If no pressure drop is preselected. sizing purposes. use 5 psi or 5% to 10% of maximum pump discharge pressure for Users Guide by Dr. Hans D. Baumann, WV

For additional information refer to Controol Valve Primer-4 a book published by the Instrument Society of America.

VALVE

CHARACTERISTIC

The purpose of a valve flow characteristic is to linearize the installed relationship between actuator signal change and change of flow rate through the valve as much as possible. This ideally assures a constant gain of the control valve. A Unear Characteristic does this only if the pressure drop across the valve is fairly constant,

The Equal Percentage or Modified Equal Percentage Characteristic, on the other hand, does compensate for varialrons in pressure drop with flow rate and should therefore be preferred if the AP vanes morefhan 2:l between min. and max. Row. Another reason why this characteristic is preferred, is the fact that such a plug is still substantially off the seat with small flow rates. For example. a 2 Vport plug at only 1.7% of max. C, is still at 10% of rated travel.

-2-

FORMULAS
FOR LIQUID SERVICE Subcritical Flow when AP is less than F, CAP,) Volumetric

FOR SIZING CONTROL

VALVES

Critical Flow when AP is more than or equal to F, (AP,) Flow c,=Q - Gf FL J APs

Where: C, = Valve coefficient C,, = Rated Cv of Valve Selected d F, F, F, G G, PI = Valve diameter (inch) = Pressure Recovery Factor = Reducer Correction Factor = Viscosity Correction Factor = Gas specific gravity (air =l .O) = Specific gravity @ flowing temperature = Upstream pressure, psia Fd = Valve Style Modifier

I Flow by Weiqht
C = W 5OOpp /

W c, = 500FL,&hP,

FOR GAS AND STEAM SERVICE Subcritical Flow when AP is less than F: (P42) Volumetric G= &4X Critical Flow when AP is more than FL2(PJ2) Flow G= Flow by Weight
c, = W 3.22,f&P(P,+p;IG, * c,= W 2*0F,P,&

P* = Downstream pressure, psia AP = Pressure drop P,-P2, psi PC = Pressure at thermodynamic critical point, psia (water = 3206 psia) P, = Vapor pressure of liquid at flowing temperature, psia

AP, = Maximum AP for sizing Use: P,-P, when outlet pressure is higher than vapor pressure. I
use: P+.96-0.2E++"

-\

For Saturated
W C = 2.1JdP(P14P,)

Steam
W c, = 1.83F,P,

when outlet pressure is equal to or lower than vapor pressure. 0 9 T = Gas flow rate at 14.7 psia and OF., scfh = Liquid flow rate, U.S. gpm = Flowing temp., R.(460+F)

For Suuerheated
W( 1 + 0.0007 C" = 2.1JAP(P,+P,) T*J

Steam
c,= w~1+o.ooo7T,h) 1.83F,.P,

NOTE: When rotary valves are installed between reducers use C,F, instead of C, (in capacity tables). OTHER METHODS: c, = & ; c, x -%; -3-

T,h = Steam superheat, OF W = Flow rate, pounds per hour Water =1 @ 60F

XT=

.84F,*

FL = m;

FL = C,/.QO

VISCOSITY

CORRECTION

Where highly viscous fluids (usually above 40 cSt) or small flow conditions are encountered, it will be necessary to correct the calculated C, turbulent, by dividing C, turbulent by F,, to ensure sufficient capacity of the selected valve. R For small flow valve trim where C, r~ 0.1, this has to be done, regardless of viscosity, even if the flow medium is a gas. FOR GASES FOR UQUIDS c rOr,-d fk C~..,hrlsit -WV

Then determine Laminar Flow Gm > O-5) Laminar Flow (C, s 0.5) Transitional (AlI GA

F,. using the lower of F, or Fd: F, = 0.776 Fn = 0.026& F,' = JRey/

(c,/dZ)

Use Cv, at least 2 times the calculated This may have to be inCv turbulent. creased later if calculations show selected CvR is too small. Where n = 1 +(89Od%&*) + log (Re,) n = 2 + log (Re,) for small flow valves (C,,, < 0.5). NOTE: Minimum n = 2

Flow

Do not use this equation for Re, values below 10. Where Re, (Valve Reynolds Number):

FOR LIQUIDS
Rev= 17300 Fd q

FOR GASES

VpT-Ci v - Kinematic Viscosity (centistokes), if vfscosity is in Centipoise (u), divide u by G, to obtain v. For gases use Y at atmospheric conditions. For other definitions, see page 3.

F,, (Valve Style Modifier) and F, (Pressure Recovery Factor) For Standard Valves: 84000/86000
F, = 0.35 Globe Valves Fd = 0.46 Butterfty Valves, F, = 0.30 70' (Open) See Cv Tables For Others F, = .80 F, = .90 F, = .70 V-Port & Splined Trim Mikroseal C, 2 0.3 Tapered P?gz Ffi. 102) Fd = 0.7 Fd = 0.2 2 1 i:ic F, = .98 F, = .85 : f 1::

Example:

Bunker C Oil @ 1loOF, P, = 100 psig, P, = 75 psig, G, = 0.99. q = 70 gpm, v = 1100 centistokes Re " = 17300 x .45 x70 1100 J.9 x28 = 0.776
,fitii/(28/1.5=)=0.63

= 101

So, salact pfug,rated

l-112 Globe valveve, parabolic C, = 28, FL =0.9, Fd = 0.46

F~ C"a-

= 13 = 22.1 0.63 (O.K. 79% of Rated CJ

d-

Cv Table
SERIES 24000 BRONZE LllTLE
20 1

SCOlTY
30 , 40 j

CONTROL
50_-,www60 i

VALVE
1 80

Cv Table
SERIES 24000s STAINLESS
5 1~ 10 ! ILUG 11 RAVEL IIN.) RATED CV (FLOW TO OPEN) 1

STEEL
20 30

CONTROL
40 -70~609

VALVE
70 1 80 1 00 j TM.,, ~66~~6 hECOVERY FACTOR (FL) VALVE SlYLE MODIFIER (Fd

ERCENTAGE OF PLUG_TRAVEL+ALVE MODEL ., PORT SIZE IIN.) NO. DIA. IIN.) -

0:

006 I 009 a 13 01s 08

046

i
1246775: i--iG?x 375 375

0 08

c c c

10

12

019 uz9 52

pas

813

046 I 2458% 150

-6-

SERIES

21000E~A~_T_OMER

LINED

BUlTERFLY

VAtyE

~~~~~~~~~~~,-~-~~~~~~:~~~::~. -~~~ 3
4 1 6' -

. i 2.5 1 . 05 +
12 25 6 T-125

8
16 35

1
: 19 28 69 39 56 139 64 97 229 ? 91 132 327 121 180 441 154 232 566 190 292 707 I

216 354 1 836

-- _ ~;I0
025

230

i .a65 .a5 85

79

435

77

0.74

975

77 j

0.22

6' 8 lo' 12

i I T31 i

15 20 45

32 ____ 45 73 I I 105

a0 102 174

130 195 265 t

190 310 474 6a0 I

265 465 665 960

345 695 750

750 __!Xe

16' : 65 164 391 (lbF~- Pressure recweqfactor (2\ KC - Coetf~cmt of inclptentcavdatm (3)Fp- Mult1plyva~erat~dC~byFp1pcompensatefor (D=lrnesire/d=valveslre)

570 ._ _ 1060

- 1080 16i5 _ 1500

reducer losses

r~

SE~I~S~26O~O~CORRO~lON
VALVE ,i%, i ; i 1' j MODEL NUMaER 26OOl PORT. j PLUG ;TRAVEL; / (%I, j (INCH) j I .312 / i I j 312 312 312 ,312 : : T ; : .50 50 SO 50 50 5

RESlSTANTCONTROL-VALVE
PERCENTOFPLUGTRAVEL(flowloopen, 10 20 30 40 50 i 60 70

.____
a0 90 IOOFL { .' 02 05 1 1

Fa

;.OOOG'XQLl~~ .OoOjS .00015 .0005 ; 00007 I 0001 j 0003 j 008

00013~ooO24,ooO36 0004 mo4 .OOl .OOOi ..0009 .(X)08 ,002 m13

.00048~,00060;

0007 1 OOO8~lOO9I~l ?.0033 ..004!00~; 7- / .007 o09;mllm

226005 76070 26100

50~0004

26010~.312

XNl12 ;,0018.1.0025 t ! ,002 : qoc&lo5

.0oa2~~06~~?008

.?017 i 0031 j .0048 Y ,007 1 ,010 j .013 j 004 ; .008 1 ,012 ,017 : ,023 ! .033 !

iQ~O50

VALVE,

MODEL

PERCENTOF~UAT~RTRAVEL

CAVITATION
Cavitation (Fig. 1b) occurs with liquids only when high velocity reduces the static pressure inside a valve to below the pressure level at which the liquid starts to boil and produce vapor bubbles. These vapor bubbles collapse whenever the downstream pressure is higher than the so-called vapor pressure (PJ causing very high pressure waves. These implosions are responsible for a very high noise level and for great damage (under prolonged service) of the affected valve body or trim parts. Avoid the damage level of cavitation by not allowing the valve pressure drop to exceed K, x (P,-P,). Use of the Lo-T rotary control valve is beneficial, since the teeth reduce the size of the vapor bubbles and deflect the implosions away from the vane. If the process permits, air injection can be applied with the Lo-T valve to greatly reduce cavitation noises. Note, a process called flashing (Fig. 1~) will occur if the downstream pressure is equal to or less than the vapor pressure P,. This process is relatively harmless and there is no noise problem as long as high outlet velocities are avoided (connect outlet directly to flash tank or condenser) and as long as stainless steel or chrome moly body and trim are employed.

INCIPIENT CAVITATION
Cavitation in a valve is usually a gradual process beginning with only small portions of a plug or vane experiencing vapor bubbles. This so-called incipient cavitation, which is relatively harmless, will start to occur when the following pressure drop in a valve is exceeded: - Kc O,-A *pm & = Coefficient of incipient cavitation vanes typically between P, = Valve inlet pressure (psia) P, = Vapor Pressure of liquid at flowing temperature (Water @ 70F = 0.38 psia)

Where:

0.2 and 0.4.

DAMAGE INDUCING CAVITATION

Pressure drops high enough to produce be avoided, parficularly over prolonged limit, the following rules may serve as AP damage Where: K,=K, x K,xFL3 K, = (l/d).2s 6 = (loo/p,).~ d = Valve Size, Inches significant damage (and usually objectional noise levels) should time periods. While there is no exact scientifically established a guide: = K, (P, - P,) P, = Inlet Pressure (psia) P, = Outlet Pressure (psia) P, = Vapor Pressure (psia)

MAX. INLET PRESSURE

TO AVOID EXCEEDING

90 DBA CAVITATION

NOISE OF LO-T VALVES

Medium: Valve Size: Max. P, (Psig)

Cold Water at atmosoheric downstream oressure. 2 150 3 105 4 65 6 45 8 42 ,O, 32 12 25 16 20

1 pt

NOTE: The above figures are based on the valve being approximately 2/3 open. NO CAVITATION CAVITATION FLASHING
I Pl I P%

---B-B*-

--t-----y ------I -t----\,_,; -

t----1 FmJRF 18

I FlGUAE lb

I FIGURE Ic

FULL CAVITATION
Full cavitation or choked flow will be reached if a critical pressure drop (AP,) is exceeded. AP, = F, (P, - P,) Where: F, is the Pressure Recovery Factor. For globe valves, full area trim: V-Port plug = 0.98 Parabolic plug = 0.90 Lo-T = 0.7 @ 100% travel (see page 7)

AVOIDANCE

OF CAVITATION

If possible, cavitation should be avoided by using valves having a higher F, factor, by reducing the pressure drop across the valve or by increasing the outlet pressure (elevation, etc.). Resistance plates are sometimes applied to absorb some or most of the valve pressure drop when placed downstream of the control valve. Another method is the application of two valves in series (separated by at least six pipe diameters). The overall Kc or FL of such a combination is the square root of each individual F, factor. The F, required to avoid damage producing cavitation must be more than:

For example:

One 8 Lo-T valve near wide open has an F, factor of 0.72. Two valves in series have a combined F, of m= .84. thereby increasing the allowable AP by about 58%! Note: It is important that both valves be identical. Assuming an inlet pressure of 115 psia. the two valve K,, = (118) < x (1001115) x 0.84j = 0.45 compared to a & of 0.28 for a single valve. & While it may not be economical to avoid cavitation in all cases, care should be taken not to exceed the 90 dBA OSHA limit since noise and wear are interrelated. See table on page 8. May be supplied by l-f. D. Baumann Assoc., Ltd., see Bulletin RP-3.

AERODYNAMIC

VALVE NOISE PREDICTION

The calculation of the aerodynamic noise level for control valves is based on methods established by Hans D. Baumann which are concurrent with ISA Standard 75.17 (1989). They are further modified to suit the particular low noise characteristics of the Lo-T line. The method has been verified by air and steam tests on selective sizes and it is believed that the calculations yield typical accuracies of within + 3 dBA. However, the somewhat simplified equations shown below are accurate for globe valves only if the actual C, is less than 65% of maximum rated C, or less than 9 C, per valve diameter squared, and at valve outlet velocities of less than 0.1 Mach. For higher Mach numbers see correction below. A pocket calculator solvable calculation method is shown below. A simplified graphical method for field use and quick estimating purposes for the Lo-T valve is shown on page 11. SPL = 48 + 10 log(C, F, P, P,) + 5 log(D) - 20 log&,) dBA @ 1 m from outer pipe wall. Where: C, FL - 20 log(D/d) + n,,, + 20 log(F,) + F. + L, in

kd

= Flow coefficient under actual conditions = Pressure Recovery Coefficient = Inlet pressure, psia = Outlet pressure, psia = External pipe diameter (inch)

P,
P2 D d t Lo F,

= Valve Size (inch) = Pipe wall thickness (inch) = Pipe wall thickness Schedule 40 pipe = Valve style modifier (see Page 4) For Lo-T Fd = 0.30 (2), 0.25 (3). 0.24 (4) 0.22 (6), 0.18 (8 - 16) For globe valves F, = 0.33 @ 65% of Rated C,. Otherwise F,, = [(e/2.4) + 6 I 1001; 4 = % of max. rated C,.

= For globe valves: 25 log (P,/P,-1) below PJP, = 2.5. and I .75 + 15 log(P,/P,-1) above 2.5. = For Lo-T rotary valves: 12 log(P,/P, - 1.05)

%l F,

= Gas property correction factor = 10 log [(C,) x (G,)T - 122. (C, = Speed of sound in gas (f/s). G, =Specific gravity of gas) Saturated Steam Superheated Steam Natural Gas Air Helium -2 1; 0 +1 O.O23P, C,F, D2 P2 1 )I Valve Noise Based on Modified Free

Mach Number Correction:

L, = 26 log

8aumann, H.D. 1987, A Method for Predictin Aerodynamic Jet Noise Theories ASME paper 87-WA/NC h -7. -lc-

Lo-l

AERODYNAMlC
RATIO 2 1.2 1.5

NOISE PREDICTION
P,/P2 3 [PSIA! 4 5 6 7 a910

(air.gas.steam)

PRESSURE 105:

100 / 95 /

6 /

P,: 115 PSIA

I 110

70 PRESSURE RATIO P,/P2 IPSIAI

a5

Calculate ratio PI/P,, follow with valve size.

P,/P2 line to valve size and read SPL at intersection (rated G). For flow at 40%,

Above values based on 80% rated valve capacity rated G. subtract 3 dBA.

SPL based on Sched. 40 pipe. For Sched. 80, subtract 5 d0A. Note: If inlet pressure is half as shown, subtract 6 dBA. If inlet pressure is twice as shown, add 6 dBA. -1%