Chapter-18 Calculation Examples

Table of contents
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
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
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
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

Table of contents

Calculation and selection of a control valve for liquids Page 001 of 050
18. Calculation examples

18.1 Calculation and selection of a control valve for liquids
Task: Calculation of the flow coefficient (Cv-value) and sound pressure level. Specification
and selection of a suitable control valve (single seat version) with pneumatic diaphragm
actuator. Fluid: Water. The process data follows from the following table:
Description Minimum Normal Maximum Unit

Flow 10000 30000 40000 kg/h
Inlet pressure 35 28 20 bar
Outlet pressure 16 16 16 bar
Temperature 90 90 90 °C
Inlet density 962 962 962 kg/m3
Vapor pressure 0.71 0.71 0.71 bar
Critical pressure 221 221 221 bar
Viscosity 0.33 0.33 0.33 cSt
Table 18.1.-1: The process data
The pneumatic diaphragm actuator must be able to close against a differential pressure
of 40 bar. Manual operation is an additional requirement. The function is direct (valve is
open on air failure-stem retracts). The intensity characteristic of cavitation and the limit of
the outlet velocity will be checked. If severe cavitating occurs a hardened or armored trim
should be chosen. Control valve accessories are required: I/P positioner and pressure
regulator. Furthermore, a material certificate in accordance with 3.1B is necessary. The
permissible sound pressure level is 85 dB(A).
18.1.1. Solution
18.1.1.1 Calculation of Cv-value, selection of valve characteristic and nominal
size.
The three different Cv-values are first computed. They are based on the following:
FL = 0.92; XFz = 0.28 at operating point qmax.
W
Cv =
27.3 ⋅ Fp ⋅ FY ⋅ FR ⋅ ∆ p ⋅ ρ
The factor FP becomes 1.0, since pipe size = valve size. This is also valid for the factor
FR, because the fluid is water with a viscosity ν of 0.33. The factor Fy first requires the
determination of FF:
pv 0.71
FF = 0.96 − 0.28 ⋅ = 0.96 − 0.28 ⋅ = 0.96 − 0.0159 ≅ 0.94
pc 221
When inserting this figure into equation (5-9) we get:

Page 002 of 050 Chapter 18. Calculation examples
p −F ⋅p 28 − 0.94 ⋅ 0.71
FY =
FL ⋅ 1 F v = 0.92 1.38 < 1.0
=
p1 − p2 28 − 16
The value of Fy must always be smaller than 1.0. If a higher value occurs, Fy must be set
to 1.0. This is also evidence that no flow limitation occurs and that the full value of the
differential pressure may be used. This gives a flow coefficient Cv as follows:
W 30000
=Cv = ≅ 10.2
27.3 ⋅ Fp ⋅ FY ⋅ FR ⋅ ∆ p ⋅ ρ 27.3 ⋅ 1⋅ 1⋅ 1⋅ 12 ⋅ 967
By application of the above mentioned equations. The following values result for minimum
and maximum flow:
Cvmin = 2.7 and Cvmax = 23.5
With the usual safety margin factor of at least 1.25 the required Cv-value results:
23.5 ∙ 1.25 = 29.4
The next higher rated Cv-value of the data sheet is 47, which corresponds to a nominal
size of DN 50. Therefore, a standard valve, DN 50 is chosen. Generally, the rangeability
Cvmax/Cvmin as well as the flow velocity should be checked. This gives the following values:
Cvmax / Cvmin ≈ 9
Rated Cv/Cvmin ≈ 17.4 ≈ 20.2% travel at Cvmin
In accordance with recommendations in Chapter 11.3.-2 a modified equal percentage
characteristic curve is chosen by selecting Series 3250. At minimum flow we get a valve
stroke of approx. 20.2 % and at maximum flow a travel of approx. 60%. These are quite
acceptable values. The flow velocity at qmax becomes:
Q 40000 ⋅ 4 π ⋅ d2
Q=
A ⋅ v, v == 5.9 m / s
= A=
A 962 ⋅ 3600 ⋅ 0.052 ⋅ π 4
18.1.1.2 Cavitation and reliability check and prediction of the noise level to be
expected
Not critical sound cavitation < 85 dB(A) up to damaging cavitation can occur if the pressure
ratio xF is considerably higher than the xFz value of the control valve. The highest pressure
ratio results from:
p1 − p2 35 − 16
= xFz = ≅ 0.55
p1 − pv 35 − 0.71
The normal valve trim would indeed be damaged - like in this example at qmin
∆p > ∆pcrit. = 15 bar - if the type specific Kc or xFmr value at minimal flow would be only 0.55
or less. At a valve load of Φ ≈ 6% however, the type specific Kc or xFmr value is approx.
0.7, i.e. no cavitation damage is expected even at the highest differential pressure (see
also picture Figure 8.7.-9 for the determination of the XFz value for a seat guided ported
plug). Generally it can be assumed that control valves < DN 100 do not create sound
pressure levels > 85 dB(A) if cavitation-free flow conditions exist. This assumption is also

true in this example with sound cavitation as shown in the calculation menu of SAMSON
sizing flowchart (Figure 18.1.1.6.-1).
The Kc value is a traditional flow measured value for onset of choked flow from
former times, which also used from some manufacturers as a approximation for
detecting material damage. Today a cooperation of SAMSON AG with the Darmstadt
University of Technology using established methods for detecting cavitation
damage at flow machines (pump impellers) which also practical for control valves.
(See Reprint SAMSON WA 174 EN, http://www.samson.de/material/deadv001.htm)
Also there were researches of cavitation damage from US institutes published in the
ISA recommended practice ISA RP 75.23-1995. Both methods using roughly comparable
factors. The incipient damage cavitation factor σid (ISA RP 75.23) in the reversed form
1/σid with the new xFid factor (Research of SAMSON AG and Technical University
Darmstadt, Germany) As a first approx. the former valve factor Kc can be used because
xFid measurements not completely available on short term.
The test is time consuming, because operating at the incipient damage level of cavitation
these new factors may produce objectionable noise and vibration in a control valve; minor
indications of pitting begin on softer materials like copper or aluminum.
SAMSON AG recommend also an application dependent valve operating limit called
“manufacturer’s recommended limit” or xFmr factor1 lean on the ISA RP 75.23 practice
(1/σmr ≈ xFmr). Some valves may not have been tested due to test facility limitations. In
these circumstances, only a xFmr based on field experience, damage testing, or other
criteria agreeable to the user.
The manufacturer’s recommended limit for cavitation. xFmr, is the limit suggested for a
given valve. It may or may not coincide with other cavitation coefficients such as incipient
damage or constant cavitation. Published values of this limit are based on experience and
on the normal type of application for the valve. Published values may not be suitable for
all applications. The manufacturer also should publish the criteria for the selection of xFmr.
The manufacturer always should be contacted to verify the recommended limit for each
type of valve application.
Valve type xFmr ≈ xFid ≈ Kc ΔpCav.crit [bar]

Single-stage globe valves 0.7 15
Single-stage globe valves,
0.7 25
stellited or hardened plug/seat
Three-stage globe valves 1.0 100
Five-stage globe valves 1.0 200
Rotary plug valves 0.4 10
Butterfly valves and ball valves 0.25* 5*
* For larger sizes than 4 inch xFid and ΔpCav.crit need to be reduced to much smaller values
Table 18.1.1.2.-1: Coefficients for critical cavitation
1 Kiesbauer. J.: Control Valves for Critical Applications in Refineries.

Hydrocarbon Processing Magazine. Gulf Publishing Company.
Houston. June 2001. Vol. 80. No. 6. pp. 89-100

18.1.1.3 Valve type and trim material selection for SAMSON globe valve.
If other valve cavitation factors are available:
* xFmr can also be substitute with ≈ Kc ≈ FL3 ≈ xFid ≈ 1/σmr ≈1/σid
Start
Yes
No remark xF < xFz
?
No
Note:
xFz, Kc, xFmr Yes
∆p > 15 bar
always from database!
?
No
No
xF > xFmr = 0.7 or Kc
?
Yes
Yes
∆p > 25 bar
?
No
Critical cavitation Hardening required Cavitation sound
Figure 18.1.1.3.-1: Valve type and trim material selection for SAMSON globe valves
18.1.1.4 Cavitation sound means:

Because of xFz < xF cavitation exist, this cavitation is not in general noisy and could be in
the range 30 dB(A) < SPL < 85 dB(A).
For non corrosive fluids the cavitation is not dangerous.
If the fluid is corrosive e.g. acetic acid the high wet vapor “Vena Contracta” VC velocity
(often sound velocity) can destroy the surface material shortly. High corrosion resistant
alloys like “Hastelloy” or selection of another valve or valve downstream baffle arrangement
e.g. SAMSON AC-Trim (Anti cavitation trims) or standard trim with baffle where xFz > xF
lead to no cavitation and avoid risk of damage.

Sound cavitation for globe valves is defined in SAMSON sizing:

a) Δp < 15 bar and xFz < xF or
b) Δp > 15 bar and xF < xFmr = 0.7
"Hardened required" for globe valves is defined in SAMSON sizing:
a) 15 bar < Δp < 25 bar
b) xFz < xF and xF > xFmr = 0.7
Hardening required means:

Because of xFz < xF cavitation exist, the cavitation is not dangerous, if hardened trim
material like WN 1.4122 or Stellite is selected. A single stage standard trim can be used.
Caution! The hardened material has to withstand corrosive fluids. If the hardened material
is not suitable a multistage like AC-3 - Trim is recommended.
18.1.1.5 Critical cavitation for globe valves is defined in SAMSON sizing:

a) 25 bar < Δp < 40 bar
b) xFz < xF and xF > xFmr = 0.7
Because of xFz < xF and xF > xFmr, critical cavitation exist, the cavitation is dangerous.
Series 3240, and 3250 with hardened trims and low noise measures like AC-2 trims
or separate downstream baffles are preferred as well as AC-3 trims, specially to avoid
cavitation in a higher range of control.
c) 40 bar < Δp < 100 bar
Multi stage trim like SAMSON AC-3 Trim or AC-5 Trim for 100 bar < Δp < 200 bar -
should be used. This ranges varied for different valve sizes.
Caution! Recommended to use hardened WN 1.4122 or stellited trim material for better
long term reliability. In case of corrosive fluids special material selection or measures to
keep xF < xFz in combination with additional downstream baffles by SAMSON R&D is
necessary.
SAMSON Anti-Cavitation Trims and Devices
AC-1 Trim AC-2 Trim* AC-3 Trim AC-5 Trim

Figure 18.1.1.5.-1: SAMSON AG Anti- cavitation trims and devices.

Figure 18.1.1.5.-2: AC-2 Trim* Figure 18.1.1.5.-3: Additional baffles

with four attenuation plates (Silencer)Gas, Steam and Liquids
*up to 4 baffles could be integrated in series 3250 only at valve upstream as a very compact unit without
additional flange sealing. Alternative for all valve series up to two single baffles can be installed at valve
downstream between flanges or more than two in a compact body. (Silencer)

Flow 10000 30000 40000 kg/h
Inlet pressure 35 28 20 bar
Outlet pressure 16 16 16 bar
Inlet density 962 962 962 kg/m3
Vapor pressure 0.71 0.71 0.71 bar
Critical pressure 221 221 221 bar
Viscosity 0.33 0.33 0.33 cSt
Calculation results
Cv calculated 2.7 10.2 23.5
Cv required / type /size Cv100 = 47; Type 3251; NPS 2
Rel. travel %
27 61 81
f(characteristic e.q.%)
SPL (EN 60534 8-4) 74 78 64 dB(A)
Outlet velocity U2 1.46 4.39 5.86 m/s
xFz(p1) from valve data base 0.4 0.32 0.26
xF 0.55 0.44 0.21
xFmr 0.7
Incipient Incipient No cavitation
Reliability check:
or sound or sound U2 < 8 m/s
Follow the green and blue
cavitation cavitation OK
path in the flowchart Fig.
U2 < 5 m/s U2 < 5 m/s
18.2.-3
OK OK
Table 18.1.1.5.-4: Results of the Cv – and reliability check of three operating points.
Here Type 3251 DN 50 is selected because of the equal percentage characteristic high quality.

SAMSON SVSS calculates for PVC 4711
a) Plant characteristic b) Installed flow characteristic
d) Cv characteristic Type 3251

c) SPL characteristic
Cv100 = 47 modified equal percentage
Figure 18.1.1.5.-5: SAMSON SVSS calculates for PVC 4711 a) plant characteristic; b) installed flow
characteristic c) total SPL characteristic and d) Type 3251 DN 50 Cv100 = 47 modified equal percentage
characteristic. Other types of characteristics can be generated as well.
18.1.1.6 Valve selection flowchart

The selection flow chart for liquids Figure 18.1.1.6.-1 shows, how the SAMSON Sizing
and Expert software make decisions for the results of example 18.1 (with the green line
for (qmax) and the blue line for (qnorm and qmin) of this case study.
Table 18.1.1.6.-2 include general reliability recommendations for globe valves, rotary plug,
and butterfly control valves. If in a liquid application the SPL value cannot be limited to <
85 dB(A) recommended with the limitation of the value x5 in Table 18.1.1.6.-2 SAMSON
R&D has to do a stress analysis and has to decide the optimum valve performance in
case of sound level > 85 dB(A).

SAMSON AG Start
Valve selection flowchart All liquids with p2 > pv
1 Avoid or minimize cavitation.
Angle type globe valve with
Notes to flowchart Abrasive Yes hardened or ceramic trim and
see next Page fluid outlet liner (FTC) or Rotary
x ? Plug Valve hardened or
No ceramic disk and outlet liner.
(FTC = Flow To Close)
No
xF > xFz
?
Yes
Design with
Yes
xFz > xF
available
?
2
No
4 3
Yes ∆p > x1 AND xF > x4 Yes

x4 = xFmr = 0.7 ∆p > x3
appr. (Kc or FL3) ?
?
No
SPL > x5 Yes
No 5
?
6
No No
SPL > x5
?
Standard Globe Valve (top guided)
Series V2001; (seat guided) Series
Yes
3240, and 3250.
Yes
∆p > ∆pcrit. = x2 Standard Rotary Plug Valve without
? measures.
Standard Butterfly Type 3331, and
No
Type 3237, Leusch, Pfeiffer or
Segment Ball Valve Type 3310 etc..
No
Hardened trim/disk and/ ∆p > ∆pcrit. = x3
or seat area for: ?
Standard Globe Valve Hardened trim/disk and/or seat area
(Top guided) Series Yes for: Heavy duty design: Series 3240,
V2001; (seat guided) and 3250. Seat- or top and bottom
Series 3240, and 3250. Hardened trim / disk and / or guided plug. Anti-Cavitation AC trim
Standard Rotary Plug seat area for: low noise measures: Baffles, etc..
Valve. Multi-stage Anti Cavitation AC-3 High performance rotary valves. In
Standard Butterfly - Type Trim, and AC-5 Trim. case of mechanical overstressing
3331, and Type 3237, Heavy duty design, Special limits reduce ∆p with multi-hole
Leusch, Pfeiffer. Segment rotary valves with multistage low downstream baffles or silencer.
Ball Valve Type 3310 etc.. noise devices. Proper downstream piping.
Figure 18.1.1.6.-1: SAMSON sizing selection flowchart for liquids (pv > p2)

High sound, damage and stress prevention
Standard Globe Rotary plug Butterfly / Ball

x1 15 bar 10 bar 5 bar**
x2 25 bar 15 bar 10 bar
x3 40 bar 20 bar 10 bar
x4 0.7 0.4 0.25
x4 Critical damage ∆p ratio like xFmr = 1/σmr (also published Kc approx. FL3)
SPLlimit ≤ x5
x5 85 db(A) 85 db(A) 85 db(A)
Butterfly valve
6 to 8 inch 10 to 12 inch 14 to ...inch
**x1
3 bar 2 bar 1.5 bar
The flowchart shows recommendations to select valve types for standard and critical
liquid applications taking long term reliability operations into account. Valve type specific
values x1 to x5 here are default values from a conservative point of view based on
experience and measurement.
Notes to flowchart:
1 Abrasive and corrosive fluids Risk of damage, keep U2* < 3 m/s
To avoid piping noise and vibration

2 No cavitation: Keep U2 < 8 m/s up to Class 300
Keep U2 < 10 m/s at Class 600 to 2500
3 x1 = ∆p damage potential x4 = ∆p ratio damage potential
4 Critical cavitation Risk of damage, keep U2* < 3 m/s
5 Incipient- or sound cavitation Risk of damage, keep U2* < 5 m/s

Values higher x5 need agreement of SAMSON
6 SPL = Sound Pressure Level
R&D
*If the fluid is less under- cooled - 0.44 bar < p2 - pv < 1,25 bar - U2Limit can float between
3 m/s (severe cavitation) and 5 m/s (incipient cavitation) following the equation:
m p − pv m m
3 < 4.5 ⋅ 2 ⋅1 < 5
s 1bar s s
Table 18.1.1.6.-2: Legend and indices to Figure 18.1.1.6.-1 SAMSON sizing

selection flowchart for liquids (pv > p2)

18.1.1.7 Actuator calculation

Based on the chosen control valve Series 3250, NPS 2, Cvmax = 47 the required actuator
thrust can be computed if the seat diameter and stem diameter are known (which are in
this example 48 and 10 mm). It must be mentioned however, that the maximum possible
differential pressure has to be considered.
Fluid force F∆p
F∆p = [(Sb2 ∙∆p) + (Sd2. p2)] ∙ π/(4 ∙ 10)
F∆p = [(482∙ (40 - 1)) + (102 ∙ 1)] ∙ π/(4 ∙ 10) = 7060 N
p1: Inlet pressure = 40 bar
p2: Outlet pressure = 1 bar
Sb: Seat bore diameter = 48 mm
Sd: Stem diameter = 10 mm
Closing force FSF

FSF = π∙ f2 ∙ Sb = 3.14 ∙ 2 ∙ 48 = 301 N
f2 = 2 N/mm for leak rate Class IV
Packing friction FR with a braided PTFE-Packing

FR = π ∙ f1 ∙ Sd = 3.14 ∙ 3.2 ∙ 10 = 100.48 N
f1 = 3.2 N/mm
Weight force FM here negligible.
Required actuator thrust

Fa = Fo req.[kN] = 7.46
Fa = F∆p + FSF + FR + FM
Fa = 7060 + 301 + 100.48+0
Fa = 7461 N = 7.46 kN ①
Required diaphragm area and actuator type

With a chosen signal range of 0.2 to 0.6 bar* (actuator function is DIRECT - stem retracts)
and an available air supply pressure of 3.0 bar the diaphragm area A becomes including
a safety factor of 1.25:
A = Fa ∙ 1.25 / 10 ∙ [pst + (pst100-pst0) ∙ H/Hnom. –pst100]
A = 7461 ∙ 1.25 / 10 ∙ [3 +(0.6-0.2) H/15 - 0.6] at h = 0
A = 7461 ∙ 1.25 / 24 = 389 cm²
* Because actuator type with H = 30 mm combined with valve travel Hnom. = 15 mm.
In this case a suitable actuator type from the manufacturer’s product range is selected
with a diaphragm area of 700 cm2.

Recalculation with the chosen actuator 700 cm² spring range 0.2 to 0.6 bar and
Air supply 3 bar:
① ⑥
② ⑦
③ ⑧
④ ⑨
⑤ ⑩
Figure 18.1.1.7.-1: Pressing "Result valve"

shows the same actuator data from the manual calculation before
Actuator force at h = 0
Fa = 10 ∙ A (pst – pst100)
Fa = 10 ∙ 700 (3 - 0.6) = 16.8 kN ⑦
Close safety factor
Fa/Fo req. = 16800/7461 = 2.25 ⑧
∆pmax on plug = (Fa - FR - FSF) /10 ∙ (π/4) Sb2 = (16800 - 401.48) / 180.8 = 90.6 bar ④
Other values in SAMSON actuator sizing - here less important - are explained for better
understanding:
Required actuator thrust (Fm req.) ② Pressure balance
(see next example Chapter 18.2
Max. permissible Actuator force

Fmax ③ = Function of temperature and stem
diameter. (Construction parameter)
ps0 req. min. force pst0 ⑤, only important for fail
safe "stem extend - air to open"
(see next example 18.2)
∆ps min. = Required air supply for fail safe
“stem retract - air to close”
pst-pst100 = (∆p req.∙ (π/4) Sb/10)2 + FSF) / A ∙ 1.25
pst -pst100 = (39 ∙ (π/4) (48/10)² +301) / 700 ∙ 1.25
pst -pst100 = 1.16 bar ⑥
⑪
Min. air supply required = 0.6 + 1.16 = 1.76 bar ⑪ Figure 18.1.1.7.-2:
Max. permissible Actuator force

Hysteresis
Hysteresis % = 10 ∙ 2 ∙ FR / A (pst100 – pst0)
Hysteresis % = 20 ∙ 100.48 / 700 ( 0.6 – 0.2) = 7.18 ⑨
At least only for „stem retract - air to close“
At least only for „stem retract - air to close“

Opening safety factor FS/Fw is calculated:
FS/Fw = 10 ∙ pst0 ∙ A / (FR + c) = 10 ∙ 0.2 ∙ 700 / 100.48 = 13.9 ⑩
Small deviation to SAMSON SIZING
Fw = total friction force FR + c
c = actuator stem sealing- and other forces.
Figure 18.1.1.7.-3: Control valve Type 3251 with Positioner Type 3731-x
18.1.1.8 Example 18.1 Comparison with SAMSON SIZING

If one enters the given operating data into the corresponding calculation menu of SAMSON
SIZING and initiates a comprehensive calculation, the program will present the results of
all calculations below.

Propsl./order no.: Customer

Project: Date: 03.03.2010 Data entered by:
Item no. PIC-4711 Tag no. PIC-4711

Process medium Water State of medium at inlet: liquid Valve Sizing Version 4.74
Process and medium data Case 1 Case 2 Case 3

Flow W [kg/h] 10000 30000 40000
Inlet pressure p1 [bar(a)] 35 28 20
Outlet pressure p2 [bar(a)] 16 16 16
Inlet temperature t1 [°C] 90 90 90
Density rho1 [kg/m³] 967 967 966
Vapor pressure pv [bar(a)] 0,702 0,702 0,702
Critical pressure pc [bar(a)] 221 221 221
Viscosity ny1 [cSt] 0,326 0,326 0,326
Results and factors

Valve coeff. calculated Cv 2,70 10,2 23,5
Min. req. size Req. DN [mm] 27,0 46,8 54,1
Outlet velocity w [m/s] 1.46 4.39 5.86
SPL (EN 534 8-4) LA [dB(A)] 74 78 64
relative travel T [%] 26.9 61.0 81.4
Different. pressure ratio xF 0.55 0.44 0.21
FL value FL 0.97 0.95 0.92
xFmr value xFmr 0.70 0.70 0.70
Valve style factor Fd 0.19 0.40 0.43
xFz value at load xFzp1 0.40 0.32 0.26
Valve data
Body type Globe valve Series 3250
Valve coefficient Cv 47 Type 3251
Nominal size DN ["] 2" Body material A216 WCC
Pressure ratings CLASS 300 Noise reduction without
Travel S [mm] 15 Charact. Equal perc.
Seat bore SB [mm] 48 Flow direction FTO
Stem diameter Sd [mm] 10 Balanced without (0,0)
Internal parts material 4571 / 316Ti Leakage rate IV
Packing PTFE (3,2) Bonnet standard
Sealing metal (2,0)
Pipe data Type of pipe Steel pipe Pipe insulation none D1 [mm] 50 D2 [mm] 50
cR [m/s] 5100 rho [kg/m³] 7800 di [mm] 54.5 s [mm] 2.9
Actuator data
Type 3277 Fail-safe act. retracts
Diaphr. area A [cm²] 700 Bench range ps0 [bar] 0,2 ... 0,6
Supply psu [bar] 3
(Defaults: p1max [bar(a)] 40 p2min [bar(a)] 1 t1max [°C] 90)
Actuator results
req. act. force Fo req. [kN] 7.46 req. diff. psu-ps100 d ps [bar] 1.17
max. act. force Fmax [kN] 24.97 Actuator force Fa [kN] 16.80
max. dp on plug d. pmax [bar] 90.61 Close safety factor Fa/Fo (SF) 2.25
req. start bench range ps0req. [bar] 0.02 Open safety factor Ff/Fw 13.64
Figure 18.1.1.8.-1: Calculation menu of SAMSON SIZING for liquids (Example 18.1)

SAMSON SIZING confirms the previous results. The actual sound pressure levels are
74, 78 and 64 dB(A). i.e. well below the permissible value of 85 dB(A). Partial sound
cavitation occurs, but without risk for material damage or stem vibration if a top and seat
guided contoured plug of series 3240 and 3250 are selected.
The valve load at maximum flow is only 81 %, i.e. we have safety reserves for a possible
flow increase at a later date. The results of SAMSON SIZING for the actuator calculation
procedure follow from Figure 18.1.1.8.-1 and Figure 18.1.1.8.-2. Also these results of the
manual calculation are confirmed by SAMSON SIZING. The effective signal range is 0.2
to 0.6 bar, caused by the different nominal travels of the control valve (15 mm) and the
selected actuator (30 mm).
Following the IEC standard 60534-2-4 SAMSON AG is calculating the real measured
inherent valve characteristic and Cv100 value to avoid any maladjustment of an additional
travel stop device if specific Cv – values have to be warranted e.g. in case of an interaction
with a safety valve.
Figure 18.1.1.8.-2: Calculation menu of SAMSON SIZING for liquids with the true stroke of 27 %, 61 %,
and 81 % at min, norm., and max. load and the true Cv100 value 45
Today all modern globe valve sizes with a competitive largest Cv100 value cannot fulfill
the tolerance limits for the true equal percentage characteristic, because of the global
competition in lower weight, travel and material cost pressure.
It is more important to have a smooth characteristic form. If relatively seldom there is a
real demand for a true e.q. characteristic valves with reduced seats or higher performance
Series 3250 may fulfill this demand.
The completely filled-in ISA Form S20.50, Rev.1 specification sheet (TAG-No. PIC - 4711)
is shown with Figure 18.1.1.8.-3.

SAMSON sizing software works together with SAMSON Project tools to generate Project
list, dimension drawings and ISA or IEC specification sheets.
Specification Form for Control Valves
According to ISA Form S20.50, Rev. 1
Project Data Sheet of

Unit Date 02.03.2010
PO Spec
Item PIC-4711 Tag PIC-4711
Contract Dwg
Mfr Serial* Service
1 Fluid Water Crit Press Pc
Units Max Flow Norm Flow Min Flow Shut-Off
2 Flow Rate kg/h 10000 30000 40000 -
SERVICE CONDITIONS
3 Inlet Pressure bar(a) 35 28 20

4 Outlet Pressure bar(a) 16 16 16
5 Inlet Temperature °C 90 90 90 -
6 Density/Spec Grav/Mol Wt kg/m^3 967 967 966 -
7 Viscosity/Spec Heat Ratio cSt 0,326 0,326 0,326 -
8 Vapor Pressure bar(a) 0,702 0,702 0,702 -
9 * Required Cv Cv 2,70 10,2 23,5 -
10 * Travel % 20,1 40,1 60
11 Allowable/Predicted SPL dB(A) 74 78 64 -
12
13 Pipe Line Size In 50 DN [mm] 53 * Type 3277

LINE
14 & Schedule Out 50 DN [mm] 54 * Mfr & Model SAMSON pneumatic

15 Pipeline Insulation none 55 * Size 700 cm² Eff Area
56 On/Off Modulating
16 * Type 3251 57 Spring Action Open/Close retracts
ACTUATOR
17 * Size 2" DN [ " ] ANSI Class 300 58 * Max Allowable Pressure

18 Max Press/Temp 59 * Min Required Pressure
19 * Mfr & Model SAMSON Globe valve 60 Available Instr. Air Max
VALVE BODY / BONNET
20 * Body/Bonnet Matl 61 Supply Pressure Min

21 * Liner Matl/ID 62 * Bench Range 0,2 ... 0,6 bar
22 End In 63 Act Orientation
23 Connection Out 64 Handwheel Type
24 Flg Face Finish 65 Air Fails Valve Set at
25 End Ext/Matl 66
26 * Flow Direction FTO 67 Input signal
27 * Type of Bonnet standard
28 Lub & Iso Valve Lube 68 * Type
POSITIONER
29 * Packing Material PTFE 69 * Mfr & Model

30 * Packing Type 70 * On Increasing Signal Output Incr/Decr
31 71 Gauges Bypass
72 * Cam Characteristic
32 * Type 73
33 * Size 48 mm Rated Travel
34 * Characteristic Equal perc. 74 Type Quantity
SWITCHES
35 * Balanced/Unbalanced without 75 * Mfr & Model

36 * Rated Cv 47 FL XT 76 Contacts/Rating
TRIM
37 * Plug/Ball/Disk Material 77 Actuation Points

38 * Seat Material 78
39 * Cage/Guide Material
40 * Stem Material 79 * Mfr & Model
AIRSET
41 80 * Set Pressure
42 81 Filter Gauges
82
43 NEC Class Group Div.
SPECIALS / ACCESSORIES
44 83 * Hydrostatic Pressure
TESTS
45 84 ANSI/FCI Leakage Class

46 85
47 86
48 Rev Date Revision Orig App
49
50
51
52
* Information supplied by manufacturer unless already specified. SAMSON CONTROLS INC. TV-SK……
Used by permission (letter to be sent to the ISA)
Figure 18.1.1.8.-3: ISA Form S20.50. Rev. 1 specification Sheet generated from SAMSON sizing project
tools for example 18.1 PIC 4711

18.2 Calculation and selection of a control valve for steam

Task: Calculation of the flow coefficient (Cv-value) and sound pressure level. Specification
and selection of a suitable control valve (pressure balanced type) with pneumatic diaphragm
actuator. Fluid: Overheated steam. The process data follows from the following table:

Flow 8000 15000 20000 kg/h
Inlet pressure 30.0 22.0 16.0 bar
Outlet pressure 6.0 6.0 6.0 bar
Ratio of specific heats Cp/Cv 1.29 1.29 1.3 ---
Table 18.2.-1: The process data of example 18.2 PCV 5711
The pneumatic diaphragm actuator must be able to close against 35 bar. The function is
REVERSE (valve closed on air failure). Air supply 4.5 bar. Control valve accessories are
I/P positioner, solenoid valve and pressure regulator. The maximum permissible sound
pressure level - considering thermal insulation of the pipeline (80 mm thick) - is 85 dB(A).
By means of an “Override”- function, which should be implemented through a three-way
solenoid valve, the valve should be able to achieve 75 % of the maximum flow coefficient
in less than one second. Furthermore, a material certificate is necessary in accordance
with 3.1B. The pipeline flanges are designed for a pressure rating of PN 40. Suitability of
the standard carbon steel material is to be checked. Otherwise a high temperature steel
body material must be used.
18.2.1. Solution
18.2.1.1 Calculation of the flow coefficient (Cv-value). selection of the valve
characteristic and nominal size.
First the three different Cv-values are calculated. They are calculated type specific in the
operating points min., norm., max: xT = 0.8; 0.77; 0.74. The respective inlet density can be
read off from corresponding steam tables. At inlet pressures of p1 = 30. 22 and 16 bar, the
corresponding inlet densities become 13.03, 9.31, and 6.64 kg/m3. The value of Fp can
simply be read off from Figure 5.4.3.-3. With a relationship of DN/D = 150/200 = 0.75 and
a ratio of Cv∙100/DN2 ≈ 68∙100/1502 = 0.3 for standard valves, a Fp value of approximately
0.99 results. For the calculation of Y first the value of Fy be must be determined.
γ 1.29
Fy
= = = 0.92
1.4 1.4

Calculation and selection of a control valve for steam Page 017 of 050
The pressure ratio results from the following:

p1 − p2 22 − 6
=x = = 0.73
p1 22
As already mentioned, for a calculation of the term Y, the value of the pressure ratio x
must be limited to the valve specific figure xT, even if the actual pressure ratio x is higher:
x < xT → 0.73 < 0.77.
x 0.73
Y=
1− 1−
= 1 − 0.367 =
= 0.643 ≥ 0.667
3 ⋅ Fy ⋅ x T 3 ⋅ 0.92 ⋅ 0.72
Since Y must be in any case between 0.667 and 1.0, the calculated value of Y must be
set to 0.667. This means that a critical pressure ratio and sonic velocity occur inside the
control valve. In this way, the flow coefficient Cv can be computed:
W
=Cv ≅ 68
27.3 ⋅ Fp ⋅ Y ⋅ 0.73 ⋅ 22 ⋅ 9.34
If the calculation procedure is repeated for the minimum and maximum flows, the results
are as follows: Cv ≈ 25 for Wmin and Cv ≈ 129 for Wmax.. Considering the usual safety margin
of 25 % on top of the maximum calculated Cv-value, the required Cv-value becomes:
Cv required = 129 ∙ 1.25 ≥ 161
So we select a rated Cv-value of 190. This corresponds to a nominal size of DN 150
with flow divider Type ST I or baffle type (downstream multi-hole orifice plates) which is
required to keep the sound pressure level within given limits. The relationship between
the maximum and minimum flow coefficients is as follows:
Cvmax/Cvmin @ 5.2
Rated Cv/Cvmin @ 7.6
This corresponds to a travel at Cvmin of approx. 8 % (linear characteristic) or approx. 41%
for an equal-percentage characteristic. Since normally a critical pressure ratio applies
and the required rangeability is comparably low, a satisfactory regulation can be achieved
with both basic valve characteristics.
The flow velocity in the valve outlet and the pipeline behind the valve can be roughly
computed if we assume a steam density of 2.45 kg/m³ at 6 bar and a fluid temperature of
275°C. This corresponds to a maximum flow volume of approx. 8042 m3/h at maximum
flow. The fluid velocities are as follows:
8042 8042 m 8042 m

U2 ≅ 350 ⋅ 2
≅ 350 ⋅ 2
≅ 125 or 350 ⋅ 2
≅ 70
150 150 s 200 s
These velocities are rather conservative and are quite acceptable.

18.2.1.2 Calculation of sound pressure level at normal flow

In this example the SPL calculation is based on the VDMA 24422 Edition 89 method that
is widely used in Europe. The factor xcr is calculated as follows:
γ 1.29
⋅1.9⋅Fk ⋅x T ⋅1.9⋅0.92⋅0.77
 2  γ −1  2  1.29 −1
x cr =
1−   1− 
=  ≅ 0.555
 γ + 1  1.29 + 1 
The planned valve Type 3241 with a flow divider Type ST I shows the following exponents
G1 and G2 which are required for the calculation of the acoustic efficiency factor:
G1 = - 4.9; G2 = 0.70.
For this calculation first a check is required as to whether the following condition is fulfilled
(which is the case in this example):
lg (1 − x ) γ +1
≤
lg (1 − x cr ) γ −1
lg (1 − 0.73 )
= = 1.59
lg (1 − 0.555 )
This gives an acoustic efficiency factor ηG:

G2 0.75
G  lg (1 − x )   lg (1 − 0.73 ) 
ηG =
10 1 ⋅   10−4.64 
=  ≅ 0.00003282
 lg (1 − x cr )   lg (1 − 0.555 ) 
The inner sound power can be computed with the acoustic efficiency factor and the given
operating data:
γ p1 lg (1 − x )
L= 134.4 + 10 ⋅ lg W + 10 ⋅ lg + 10 ⋅ lg + 10 ⋅ lg + 10 ⋅ lgηG
lg (1 − x cr )
wi
γ +1 ρ1
1.29 22 lg (1 − 0.73 )
L = 134.4 + 10 ⋅ lg15000 + 10 ⋅ lg + 10 ⋅ lg + 10 ⋅ lg + 10 ⋅ lg0.00003282
wi 1.29 + 1 9.34 lg (1 − 0.555 )
≅ 134.4 + 41.7 − 2.49 + 3.72 + 2.1 − 44.84 ≅ 134.6 dB
From the determined sound power Lwi, the “standardized sound power spectrum” can be
computed for the relevant frequencies:
f
L wi ( f ) = L wi + 10 ⋅ lg − 14.9
500
If the relevant frequencies 500; 1.000; 2.000; 4.000; and 8.000 Hz are inserted into the
equation above, the following rounded off internal sound power levels and transmission
losses will be achieved:

Frequency f: 500 1000 2000 4000 8000

Internal sound power
119.5 122.5 125.5 128.5 131.5
Lwi at the frequency:
Transmission loss RR 54.3 45.3 41.3 43.3 45.3
Table 18.2.1.2.-1: Internal sound power level and transmission loss
The transmission loss of the pipeline is based on the following assumptions.

Steel pipeline DN 200, wall-thickness 6.3 mm, velocity of sound in the pipeline approx.
5.100 m/s, density of steel is 7.800 kg/m3.
From the density and temperature of superheated steam the velocity of the sound can be
computed:
γ ⋅ p2 ⋅ 105 1.293 ⋅ 6 ⋅ 105 m

=c = ≅ 553
ρ2 2.537 s
The ring frequency of the pipeline DN 200 is computed as follows:
cR 5100
=fr = ≅ 8120 Hz
π ⋅ di π ⋅ 0.2
With the parameters now available, the pipe transmission loss RR can be computed:
c R ⋅ ρR ⋅ s  fr 3 5 ⋅ f 
RR (f ) = 10 + 10 ⋅ lg + 10 ⋅ lg   + f 
c F ⋅ ρF ⋅ di  5 ⋅ f  r 

5100 ⋅ 7800 ⋅ 0.0063  f 3 5⋅f

 
RR (f ) = 10 + 10 ⋅ lg ≅ 10 + 29.3 + 10 ⋅ lg  r  + 
573 ⋅ 2.54 ⋅ 0.2  5 ⋅ f  fr 
 
If one inserts for f, the relevant frequencies, the transmission loss is shown in the table
above.
The external sound power Lwa results from the following equation:
4 ⋅l
L wa (f=
) L wi (f ) − RR (f ) + 10 ⋅ lg
di
With the considered pipe length (l) of l = 2.0 m the frequency-dependent values of Lwa are
shown in the table below. Therefore, one must not simply subtract the pipe transmission
loss of the inner sound power, but must still consider the term
 4 ⋅l 
10 ⋅ lg⋅  
 di 
The external A-weighted sound power level is calculated from the individual non-weighted
sound levels when one adds the following adjustment values.

Frequency f: 500 1000 2000 4000 8000

Internal sound power Lwi
119.5 122.5 125.5 128.5 131.5
at the frequency:
Transmission loss RR 54.3 45.3 41.3 43.3 45.3
10*lg 4*l/di 17.2 17.2 17.2 17.2 17.2
External sound power Lwa 81.4 93.4 100.4 101.4 102.4
Adjustment value -3.2 0 +1.2 +1 -1.1
External sound power
78.2 93.4 101.4 102.4 101.3
Lwa a dB(A) (weighted)
Table 18.2.1.2.-2: The external A-weighted sound power level
The aggregate level, which must be naturally higher than the largest single level, must
now be computed from the individual weighted sound power levels. The specific addition
occurs by taking the logarithmic sum with the basis 10 and an exponent of 0.1 ∙Lwa as
shown in the following equation:
10 lg 107.82 + 109.34 + 1010.14 + 1010.24 + 1010.13  ≅ 106.7 dB(A)

L wa (A) =⋅
The external A-weighted sound pressure level measured at a distance of 1.0 m downstream
of the outlet flange and 1.0 m of the pipe surface, results in the case of a cylindrical
radiation, approximately from the following equation:
 π ⋅ l  di 
Lpa ≅ L wa − 10 ⋅ lg  ⋅  + 2 
 l0  d0  
 π ⋅ 2  0.2 
Lpa ≅ L wa − 10 ⋅ lg  ⋅ + 2   ≅ L wa − 11
 1  1 
When subtracting the „measuring area“ value of approx. 11 dB(A) from the evaluated
sound power level. Lwa(A), one finally gets the sound pressure level
Lpa(A): 106.7 dB(A) - 11 dB(A) = 95.7 dB(A)
18.2.1.3 Summary:
The manual calculation in the table compares with the graphic from the software
CONVAL and SAMSON sizing.
The difference between the red and green bars is the damping function of the downstream
pipe versus the octave frequency band.
Important! Index w = power, p =pressure, i =internal , a = external, (A) weighted level

Exhausting into the atmosphere produce the internal sound power Lwi (red bars). The
external sound power Lwa (green bars) is higher than the external sound pressure Lpa
(blue bars), where the total Lpa value (95.7) is normally guaranteed.

140.0 133.9
131
130.0 125 128
119 122
120.0
105.3 Lwi
110.0 99.3
100.2 101.3
100.0 93.9 91.7
Lwa (A)
88.8 89.9 87.9
90.0
77.1 80.3 Lpa (A)
80.0
70.0 65.6
60.0
50.0
40.0
30.0
20.0
10.0
0.0
Total 500 Hz 1 kHz 2 kHz 4 kHz 8 kHz
Figure 18.2.1.3.-1: Summary of the manual Sound calculation to VDMA 24422 Edition 89
Since the pipeline is provided with a thermal insulation of 80 mm thickness and the outlet
velocity of the fluid is very moderate, the correction of the computed sound pressure level
can be carried out in accordance with the equations (8-96) and (8-98). This gives the
following correction value for of the fluid velocity:
Lpa ' ≅ Lpa − ( 5.5 + lnMa ) ≅ 95.7 − ( 5.5 + ln0.18 ) ≅ 3.78 dB(A)
Considering a pipe insulation of 80 mm thickness the relevant correction value is as

follows:
Lpa ' ≅ Lpa − ( 4.5 ⋅ lg insulation thickness ) ≅ 4.5 ⋅ lg80 ≅ 8 dB(A)
In this way, the total adjustment value becomes 3.78 + 8 dB(A) @ 11.7 dB(A), which can
be subtracted from the previously calculated sound pressure level. This gives a sound
pressure level at a distance of 1.0 m from the pipe surface at normal flow condition:
Lpa ' ≅ 95.7 − 11.7 ≅ 84 dB(A)
The tolerance band resulting from uncertainties of the calculation and from special
influences, is about 5 dB(A). In this way, the request for a maximum allowable sound
pressure level of 85 dB(A) at normal flow is guaranteed.

Frequency f: Total 500 1000 2000 4000 8000

Internal sound power Lwi at the frequency: 134.6 119.5 122.5 125.5 128.5 131.5
Transmission loss RR -54.3 -45.3 -41.3 -43.3 -45.3
10∙lg 4∙l/di 17.2 17.2 17.2 17.2 17.2
External sound power Lwa 81.4 93.4 100.4 101.4 102.4
Adjustment value (A weighted) -3.2 0 +1.2 +1 -1.1
Comparison with SAMSON Sizing and thermal isolation acc. Figure 18.2.1.4.-3
Thermal Isolation SAMSON Sizing -3 -5 -7 -7 -8
External sound power Lwa dB(A) 99.5 75.2 88.4 94.4 95.4 93.3
Measuring Area -11 -11 -11 -11 -11
SAMSON SIZING Total external
SPL Lpa dB(A) Thermal Isolation 88.5 64.2 77.4 83.4 84.4 82.3
Comparison with the manual SPL calculation and CONVAL calculation without thermal isolation
External sound power Lwa dB(A) 106.7 78.2 93.4 101.4 102.4 101.4
Measuring Area -11 -11 -11 -11 -11 -11
External sound pressure level Lpa dB(A) 95.7 67.2 82.4 90.4 91.4 90.3
Thermal Isolation acc. to eq. (8-64; 8-66) -11.7
Total external SPL Lpa dB(A) 84
Table 18.2.1.3.-2: Sound pressure level at a distance of 1.0 m from the pipe surface at normal flow
condition
18.2.1.4 Comparison with SAMSON SIZING

If one enters the operating data into the corresponding menu and carries out the calculation
and selection procedure, SAMSON SIZING presents the following results and selects
a control valve of the standard line Series 3240 with flow divider Type ST I as shown
in Figure 18.2.1.4.-1 below. To achieve this result, however, it takes a small „trick“. If
from the beginning, the maximum allowable sound pressure level of 85 dB(A) is entered,
SAMSON SIZING would automatically choose a valve with a more sophisticated valve
trim, in order to meet the specified sound pressure level of 85 dB(A) without insulation of
the pipeline.
Knowing that thermal pipe insulation might reduce the emitted valve noise between 5 and
10 dB(A), the max. permitted sound pressure level is set, in the corresponding input field
of SAMSON SIZING, a little higher say 95 dB(A) so that SAMSON SIZING will choose
the most economic solution.

The result of the manual SPL calculation for the operating point Wnorm = 15000 kg/h
→ 88.5 dB(A) fits very good to the result of SAMSON Sizing 88 dB(A) if the standard
reduction of a thermal isolation is used.
Item no. PVC 5711 Tag no. PVC 5711

Process medium Steam State of medium at inlet: vapor Valve Sizing Version 4.74

Flow W [kg/h] 8000 15000 20000
Outlet pressure p2 [bar(a)] 6 6 6
Density rho1 [kg/m³] 13,1 9,34 6,65
Isentropic exponent gamma 1,29 1,29 1,30
Viscosity eta [mPas] 0,0188 0,0189 0,0190
Results and factors

Valve coeff. calculated Cv 24.8 65.3 129
Min. req. size Req. DN [mm] 83.1 114 131
Outlet velocity w [Mach] 0.0967 0.187 0.249
SPL (VDMA 24422 1989) LA* [dB(A)] 85 88 89
Flow condition Choked flow
Different. pressure ratio x 0.80 0.73 0.63
FL value FL 0.97 0.96 0.94
xT value xT 0.80 0.77 0.74
Level exponent G1 -4.78 -4.64 -4.54
Slope exponent G2 0.75 0.75 0.75
Valve data
Nominal size DN [mm] 150 Body material WN 1.7357
Pressure ratings PN 40 Noise reduction Flow div. I
Stem diameter Sd [mm] 16 Balanced Graphite (10)
Packing PTFE (1.6) Bonnet insulating s
Sealing metal (2,0)
Pipe data Type of pipe Steel pipe Pipe insulation TemperatureD1 [mm] 200 D2 [mm] 200
cR [m/s] 5100 rho [kg/m³] 7800 di [mm] 206,5 s [mm] 6,3
Actuator data
Type 3271 Fail-safe act. extends
Supply psu [bar] 3
(Defaults: p1max [bar(a)] 35 p2min [bar(a)] 1 t1max [°C] 275)
Actuator results
req. act. force Fm req. [kN] 4.55 req. diff. psu-ps100 d ps [bar] 0.51
req. start bench range ps0req. [bar] 0.72
*The calculated sound pressure level can not be guaranteed because of the pipe insulation.
Figure 18.2.1.4.-1: Valve calculation / selection of SAMSON SIZING for superheated steam

As can be seen from Figure 18.2.1.4.-2 a very good agreement is achieved with the manual
method of calculating values. SAMSON SIZING provides in addition more information
with respect to the noise spectrum Figure 18.2.1.4.-2.

Item no. PVC 5711 Tag no. PVC 5711

Process medium Steam State of medium at inlet: vapor Valve Sizing Version 4.74
More calculation data
Flow rate Case 1 Case 2 Case 3

Piping geometry factor FP [-] 1 1 1
Reynolds num. factor FR [-] 1 1 1
Valve Reynolds num. ReV [-] 2.1537E6 3.1757E6 3.2163E6
Expansion factor Y [-] 0.67 0.67 0.7
SPL calculation acc. VDMA 24422 1989

Differential pressure ratio x [-] 0.80 0.73 0.63
In. sound power level LWi [dB] 131 134 135
Ext. sound power level LWAa [dB(A)] 96 99 100
Sound pressure level (1m) LpAa [dB(A)] 85 88 89
Mach num vena contracta Mavc [-] 1 1 1
Acoustic conv. coeff. etaG [dB] -46 -45 -45
Level exponent G1 [-] -4.78 -4.64 -4.54
Slope exponent G2 [-] 0.75 0.75 0.75
Frequency division
In. sound power level LWi (octave bands)
500 Hz [dB] 116 119 120
1000 Hz [dB] 119 122 123
2000 Hz [dB] 122 125 126
4000 Hz [dB] 125 128 129
8000 Hz [dB] 128 131 132
Ext.sound power level LWa (Octave bands)
500 Hz [dB] 72 75 76
1000 Hz [dB] 85 88 89
2000 Hz [dB] 91 94 95
4000 Hz [dB] 92 96 96
8000 Hz [dB] 89 92 93
A-weight. (octave bands correction term)

f [Hz]: 500 1000 2000 4000 8000
A-weight. -3.2 0.0 +1.2 +1.0 -1.2
Figure 18.2.1.4.-2: Detailed noise calculation with display of important noise criteria

Standard Thermal Isolation
Sound level reduction dB

0
-2
-2 -3
-4
-5
-6
-7 -7
-8 -8
-8
-10
31.5 63 125 250 500 1000 2000 4000 8000 16000
Octave Hz
Acoustical Isolation 100 mm thickness
Sound level reduction dB

10
-10
-20
-30
-40
Pipe normal size in mm
-50
50 100 200 300 400
-60
31.5 63 125 250 500 1000 2000 4000 8000 16000
Octave Hz
Figure 18.2.1.4.-3: Standard Noise reduction spectrum of thermal or

acoustical isolation using in SAMSON Sizing.

18.2.1.5 Calculation and selection of a suitable actuator

Because of the high shut down pressure of 35 bar a pressure balanced version is chosen,
in order to hold the actuator thrusts within justifiable limits.
This manual calculation explains step by step how you can find a suitable actuator type
with SAMSON valve sizing.
Assuming a seat and guiding diameter of the guide bushing of 100 mm and a valve stem
of 16 mm diameter the required actuator thrust Fmreq. becomes:
Fmreq. = Fp1 + FSF + FR + FRB + FM
Fluid force Fp1 (pressure balance-FTO-failure position open or closed)

① Fp1 pressure balanced
π π
Fp1
= ⋅ Sd2 ⋅ p=
1 ⋅ 162 ⋅ 35
= 703 N
4 ⋅ 10 4 ⋅ 10
② Closing force FSF
FSF = π ⋅ ( f2 ⋅ Sb ) = π ⋅ 2 ⋅ 100 = 628 N
f2 = 2 N/mm for leak rate Class IV
③ Packing friction FR with a braided PTFE-Packing

FR = π ⋅ f1 ⋅ Sd = 3.14 ⋅ 1.6 ⋅ 16 = 80.4 N
f1 = 1.6 N/mm Figure 18.2.1.5.-1: SAMSON
pressure balance design
(principle drawing)
④ FRB- pressure balance (Friction force)
FRB = π ⋅ f3 ⋅ Da = 3.14 ⋅ 10 ⋅ 100 = 3140 N
f3 = 10 Graphite sealing-Ring (high temperature resistant)
Da (Pressure balance cylinder diameter)
Weight force FM here negligible (Sb < 200 mm)
⑤ Fmreq. = Fp1 + FSF + FR + FRB + FM = 703 + 628 + 80.4 + 3140 = 4.551.4 kN
Before doing this a suitable actuator type from the manufacturer’s product range is
selected with a diaphragm area of 700 cm2.
Required diaphragm area and actuator Type

With a chosen signal range of 0.8 to 2.4 bar (actuator function is Reverse -stem extends)
and an available air supply pressure of 3.0 bar the diaphragm area A becomes including
a safety factor of 1.25:

Fmreq. ⋅ 1.25
=A = 711.09 cm2
10 ⋅ pst0
at H = 0, pst = 0
4551⋅ 1.25
=A = 711.09 cm2
10 ⋅ 0.8
Recalculation with the chosen actuator 700 cm2 spring range 0.8 to 2.4 air supply 3 bar:
⑥ Max. ∆pmax on plug = (Fa - FSF - FR – FRB - c) /10∙(π/4) Sd2
Max. ∆pmax on plug = 5600 - 3848.4 / 20.1 = 87.14 bar
Small deviation to SAMSON SIZING
Total friction force FR + FRB + c
c = actuator stem sealing force and other forces.
⑦ Actuator force at h=0

Fa = 10 ∙ A∙ pst0 = 10 ∙ 700 ∙ 0.8 = 5.6 kN
⑧ Close safety factor Fa/F0 req. = 5600/4551 = 1.23

which is still acceptable in comparison to SF = 1.25
⑨ Hysteresis. % = 10 ∙ 2 ∙ (FR +FRB) / A (pst100 – pst0)

Hysteresis. % = 20 ∙ 3220.4 / 700 (0.8 – 2.4) = 57.5

⑤ ⑦
⑧
⑥ ⑨
Figure 18.2.1.5.-2: SAMSON sizing shows hysteresis information 57.54 % only here and
SAMSON SVSS software recommends a larger actuator size:
A (pst100 – pst0) = (Actuator area ∙ spring range)
In case of pressure balance valves not only the shut down requirement should be the basic
for actuator selection. Because of the high hysteresis of a pressure balanced trim system
the actuator diaphragm area should be min. 700 cm2 to take a reasonable controllability
into account. Please check this always with SAMSON Sizing SPECIALIST Software.

If the hysteresis calculation results to values > 30 % the negative impact to good
controllability is too high. Specially for pressure balance valves it is recommended to use
SAMSON sizing SPECIALIST SVSS software which is checking and watching from an
expert point of view the most important failure parameters.
Figure 18.2.1.6.-1 gives a remark to the category, control loop behavior evaluation:
Instability due to high hysteresis to be expected Recommendation:
Larger actuator size: A ∙ (pst100 – pst0).
With a higher spring range (1.2 to 3.6 bar) the hysteresis decrease from 57.54 % to
38.3%. We achieve a compromise between tremendous higher cost of a larger actuator
area and still a reasonable controllability.

Page 3/4
Quote/order no.: Customer:
Item no.: PVC 5711 Tag no.: PVC 5711

Process medium: Steam State of medium at inlet: vapor
Expert
Category Noise
Evaluation Increased
Recommendation flow divider III
Category Cavitation
Evaluation -
Recommendation -
Category Flashing
Evaluation -
Recommendation -
Category Wet steam at vena contracta

Evaluation not to be expected
Recommendation -
Category Gas icing at vena contracta

Evaluation -
Recommendation -
Category Outlet velocity

Evaluation o.k.
Recommendation -
Category Ratio of seat diameter / valve size

Evaluation o.k.
Recommendation -
Category Rangeability
Evaluation o.k.
Recommendation -
Category Control loop behavior

Evaluation instabilities due to high hysteresis to be expected
Recommendation larger actuator size
Category Actuator: safety factor (Fa/Fa req.)

Evaluation o.k.
Recommendation -
Category Actuator: safety factor (Ff/Fw)

Evaluation -
Recommendation -
Category Actuator: closing force

Evaluation o.k.
Recommendation -
Category Dynamic performance of complete control valve

Evaluation -
Recommendation -
Category Attenuation plate: strength when valve is fully opened

Evaluation -
Recommendation -
Category Attenuation plate: choked flow

Evaluation -
Recommendation -
Figure 18.2.1.6.-1: SAMSON SPECIALIST SVSS Software checks the total valve performance with
actuator 700 cm² including the influence of the hysteresis to the controllability.

Figure 18.2.1.6.-2: Selection of actuator 700 cm² (spring range 1.2 to 3.6 bar), to improve controllability
with reduced hysteresis from 57.5 to 38.3 %.
⑩ Hysteresis
10 ⋅ 2 ⋅ (FR + FRB ) 20 ⋅ 3220.4
=
Hyst. % = = 38.3 %
A ⋅ ( pst100 − pst0 ) 700 (1.2 − 3.6 )
18.2.1.7 SAMSON SPECIALIST SVSS

SAMSON SPECIALIST SVSS furthermore can also present in different graphics like the
characteristics of the plant system p1, p2 versus flow; and installed characteristics versus
opening like p, SPL, Ma outlet velocities, Cv, flow, pressure, and valve recovery factors
a.o. Figure 18.2.1.7.-1 with results of Tag No. PVC - 5711.

Page 1/1
Item no.: PVC 5711 Tag no.: PVC 5711

Process medium: Steam State of medium at inlet: vapor
Diagram overview
p1 p1
p2 p2
LpAe Ma2
Kv W
x Fd
FL
xT
Figure 18.2.1.7.-1: Plant system and installed valve characteristics SAMSON sizing software works
together with SAMSON Project tools to generate Project list, dimension drawings and
ISA or IEC specification sheets.

18.2.1.8 Material selection

The material strength generally decreases more or less quickly at operating temperatures
above 120 °C. The basis for the permissible material strength are the corresponding
standards (either DIN or ASTM). According to DIN 2401 the standard carbon steel
(material No. 1.0619) allows a permissible pressure for a valve PN 40 at 250 °C, of only
32 bar. On the other hand, the high temperature Cr-Mo steel (material No. 1.7357) still
allows even at elevated temperatures of 425 °C a pressure of 35 bar. For safety reasons
the latter material is chosen for this application.
18.3 Calculation of flow coefficient for non-turbulent flow conditions

Task: Calculation of the flow coefficient for a SAMSON micro valve (low flow) Type 3510
for the regulation of ARGON gas. The valve has a conical, pin shaped plug with the
following physical size and factors: Seat diameters D0= 3.0 mm, FL = 0.95, xT = 0.75.
Description Normal Flow Units

Volume Flow (1.013 bar and 15°C) 0.46 m3n/h
Volume Flow (1.013 bar and 0°C) 0.435 m3n/h.
Mass Flow 0.776 kg/h
Inlet pressure p1 2.8 bara
Outlet pressure p2 1.3 bara
Molecular mass M 39.9 -
Density ρn (0°C; 1.013 bara) 1.784 kg/m3
Density ρ1 (320°K; 2.8 bara) 4.209 kg/m3
Viscosity *1(320°K; 2.8 bara) 5.75* 10-6 m2/s
Temperature 320 K
Ratio of specific heats Cp/Cv 1.67 -
Fy 1.193 -
Table 18.3.-1: The process data
*This example is also published in DIN IEC 60534 2-1 with other valve factors and
differences in operating data first based for the flow QS = 0.46 m3n/h and viscosity
ν = 13.38 10-6 m2/s at standard conditions 1.013 bar and temperature of 60 °F (15 °C)
The major result difference comes from using ν = 13.38 10-6 m²/s in the calculation. The
viscosity ν as a function of (T1; p1) has a high influence to the calculation of the Reynolds
number.
SAMSON as well as CONVAL sizing software are using high professional and very
accurate property calculating methods for a huge volume of fluids. The result for Argon at
2.8 bar and 320 K (45 °C) of ν = 5.75 10-6 m2/s is the right value to use in the calculation.
See Table 18.3.-1.
A new draft of EN 60534 2-1 Edition 2008 announced to use the actual volume flow
QA to calculate the Reynolds number at operating conditions f(p1;T1). QA in case of a
compressible fluid therefore can be substitute with QA = W/ρ1 as well as Qs∙ρs/ρ1;

Calculation of flow coefficient for non-turbulent flow conditions Page 033 of 050
Index s = standard conditions at 0 °C or 60 °F, 1.013 bara. The manual calculation here
with Qs = 0.46 m3n/h based on US standard conditions 60 K; 1.013 bar.
Figure 18.3.-2: Medium data of Argon

Figure 18.3.-3: Property calculation of Argon with SAMSON sizing (above) and using
the CONVAL independent tool (below) to calculate ν versus p1 and T1

18.3.1. Solution
The first step requires a verification of the valve Reynolds number Rev:
Equation (5-26)
0.076 ⋅ Fd ⋅ Q
Re v =
ν ⋅ FL ⋅ Ci
0.076 ⋅ Fd ⋅ W
Rev = ⋅c Equation (5 − 26) modified
ν ⋅ ρ1 ⋅ FL ⋅ Ci
c ≈1
If case of the common use of the kinematic viscosity ν under operating conditions the
volume flow QA is replaced with the mass flow QA =W/ρ1.
The appropriate factor Ci is, according to equation (5-25a) 1.3 times the flow coefficient
Cv. This however represents the ultimate value and is, at first, unknown. Therefore, the
flow coefficient Cv is first computed under the assumption that the flow is turbulent and
second not critical: x < Fy ∙ xT.
x 0.536
Y=
1− 1−
= 1 − 0.19 =
= 0.8 ≥ 0.667
3 ⋅ Fy ⋅ x T 3 ⋅ 1.193 ⋅ 0.75
If Rev < 10000 SAMSON AG modified Y for higher accuracy to their micro flow
measurements:
1
Y= 1− ⋅x = 1 − 0.5 ⋅ 0.54 = 0.854
2
Y = 0.854 for SAMSON Series 3510 (SAMSON SVSS)

For this example the influence for the final result is negligible. Therefore the calculation
continued with Y = 0.8
Q M ⋅ T1 ⋅ Z 0.46 39.9 ⋅ 320 ⋅ 0.998

Cv = ⋅ = ⋅ ≅ 0.0140
2250 ⋅ p1 ⋅ Y x 2250 ⋅ 2.8 ⋅ 0.8 0.54
In this way, the dummy Ci becomes: Ci = 1.3 ∙ Cv = 0.0183

The next step is the calculation of the Fd - value according to equation (5-35), where
instead of the Cv - value the dummy Ci is used:
Ci ⋅ FL 0.0182 ⋅ 0.95
Fd =⋅
2.3 2.3
=⋅ ≅ 0.101
D0 3
Now the valve Reynolds-number can be calculated:

In contradiction to the example in DIN IEC 60534-2-1 the viscosity under operating con-
dition is used in equation (5-26 modified)
(Viscosity at p1 = 2.8 bar and T1 = 320 K: ν = 5.75 10-6 m2/s)

7.6 ⋅ 10 −2 ⋅ Fd ⋅ W 0.076 ⋅ 0.101⋅ 0.776

=Rev = = 1867.3
ν ⋅ ρ1 ⋅ Ci ⋅ FL 5.75 ⋅ 10 −6 ⋅ 4.21⋅ 0.0183 ⋅ 0.95
Rev is far below a value of approx. 10.000 at which a fully turbulent flow is guaranteed.
Therefore, the conventional calculation method according to Table 5.5.1.-1 is no longer
valid. Rather the equation (5-30) must be applied and the flow coefficient must be
calculated. At first however, a repeat calculation of FR according to equation (5-30) is
required. This in turn firstly presupposes the knowledge of the radical index n equation
(5-31) for reduced trim and a transitional flow:
Rev: 10 < 1867.3∙ < 1000 transitional flow Ci/DN2 < 0.016
0.0183 /152 < 0.016 reduced trim (micro flow)
Now Equation (5-31) is valid to calculate the radical index n:
2/3 2/3
C   0.0183 
n=
1 + 127 ⋅  2i  =
 152  1.24
=
d   
If the exponent n is inserted in equation (5-30) applies:
 0.33 ⋅ 0.95   Rev   0.33 ⋅ 0.95   1867.3 

FR =
1+   ⋅ log10   1+ 
=  ⋅ log10  =0.778
 n 1/4   10000   1.24 1/4   10000 
   
For a control of the exiting flow condition, the value FR according to (5-32) must be
calculated. The lower of both values from (5-30) and (5-32) must be used for the final
calculation of the flow coefficient Cv:
0.026 0.026
F=
R ⋅ n ⋅ Re=
v ⋅ 1.24 ⋅ 1867.3
= 1.31
FL 0.95
Maximum = 1
Therefore, now calculated is a value for FR = 0.778 which is inserted in the following
equation (5-44) with a factor 1590 for STD condition 15 °C for a non turbulent flow :
Q M ⋅ T1 0.46 39.95 ⋅ 320

Cv = ⋅ = ⋅ ≅ 0.017
1590 ⋅ FR ∆ p ⋅ ( p1 + p2 ) 1590 ⋅ 0.778 1.5 ⋅ (2.8 + 1.3)
Finally, an examination must be carried out as to whether the following condition is valid:
C 0.014
<C
=i = 0.018 < 0.0182
FR 0.778
If Cv/FR > Ci the task must be repeated where the value for Ci is raised again by around
30%. The new value of Ci = 0.0182∙1.3 = 0.0237 now must used for the calculation of Fd
and the same iteration process continue until Cvn/FRn < Cn. This however is not the case
in this example.

Therefore selected is a control valve SAMSON AG Type 3510 DN 15 with a Cv100 value of
0.030 and a linear characteristic*. It should be mentioned that the correctly computed flow
coefficient with non-turbulent flow conditions from (5-44) Cv = 0.017 is about 22% higher
than the calculated Cv for turbulent flow 0.0141.
*In general linear valve characteristic should be preferred in case of high viscosity fluids
or/and low Reynold numbers which result to non turbulent flow conditions.
Specially in case of liquids the linear Cv characteristic will tend to an equal percentage
flow characteristic, even in case of constant pressure differential. See Figure 18.3.1.1.-1.

If one enters the given operating data into the corresponding calculation menu of SAMSON
SIZING and initiates a comprehensive calculation, the program will present the results of
all calculations below. See Figure 18.3.1.1.-2.
The manual calculated Cv = 0.017 is identically with the computed Cv = 0.0167.
The Volume flow of 0.435 here m³n/h based on 0 °C, 1.013 bara

Figure 18.3.1.1.-1: Characteristic calculation shows the impact of non turbulent flow to the installed flow
characteristic (even in case of gases PVC 6711)


Item no. PVC 6711 Tag no. PCV 6711

Process medium Argon State of medium at inlet: gas Valve Sizing Version 4.74

Flow Qn [m³/h(N)] 0.435 0.0435
Inlet pressure p1 [bar(a)] 2,8 2,8
Outlet pressure p2 [bar(a)] 1,3 1,3
Inlet temperature t1 [ K] 320 320
Molar mass M [g/mol] 39.9 39.9
Isentropic exponent gamma 1.67 1.67
Real gas factor Z 0.998 0.998
Viscosity ny1 [mm²/s] 5.75 5.75
Results and factors

Valve coeff. calculated Cv 0.0166 0.00246
Min. req. size Req. DN [mm] 1.18 0.375
Outlet velocity w [Mach] 0.00187 1.872E-004
SPL VDMA 24422 mod. LA [dB(A)] <30 <30
relative travel T [%] 56.0 4.93
Different. pressure ratio x 0.54 0.54
FL value FL 0.95 0.95
xT value xT 0.75 0.75
Valve style factor Fd 0.10 0.10
Level exponent G1 -4.34 -4.33
Slope exponent G2 1.50 1.50
Valve data
Valve coefficient Cv 0.03 Type 3510
Pressure ratings PN 16 Noise reduction without
Travel S [mm] 7.5 Charact. Linear
Stem diameter Sd [mm] 4 Balanced without (0,0)
Packing PTFE (1.6) Bonnet standard
Sealing metal (2,0)
cR [m/s] 5100 rho [kg/m³] 7800 di [mm] 17.3 s [mm] 2
Actuator data
Supply psu [bar] 1.00
(Defaults: p1max [bar(a)] 5 p2min [bar(a)] 1 t1max [ K] 350)
Actuator results
Figure 18.3.1.1.-2: Calculation of SAMSON Valve Sizing PVC 6711

Page 3/3
Item no.: PVC 6711 Tag no.: PCV 6711

Process medium: Argon State of medium at inlet: gas
Diagram overview
p1 p1
p2 p2
LpAe Ma2
Kv W
x Fd
FL
xT
Figure 18.3.1.1.-3: Sizing with SAMSON Specialist SSVS Kv = 0.014 = Cv = 0.0167 and graphics of
different installed characteristic curves

Examples to the actual International Standard Page 041 of 050
18.4 Examples to the actual International Standard

CEI IEC 60534-8-4 Second Edition 2005-08
Industrial-process control valves – Part 8-4: Noise considerations – Prediction of
noise generated by hydrodynamic flow.
The examples from the actual standard are calculated by using the complete set of
equations 8-72 to 8-94b and showing the results of each equation step by step. Here
the three examples are published with SAMSON sizing to underline some important
differences between each example.
Given data:
Valve
Single seat globe valve (no multi hole trim) installed flow to open
Valve size: DN 100
Nominal valve size: d = 100 mm = 0.1 m
Rated Cv: CvR = 195
Required Cv: Cv = 90
Seat diameter: do: 100 mm = 0.1 m
Liquid pressure recovery factor: FL = 0.92
Valve style modifier: Fd = 0.42
Differential pressure ratio of incipient cavitation noise corrected for inlet pressure calculated
with equations 8-74a and 8-74c.
Example 1 Example 2 Example 3
xFz(p1) = 0.2386 xFz(p1) = 0.2386 xFz(p1) + 0.1 = 0.3324
Table 18.4.-1: Final results for xFz(p1) of example 1 to 3
Pipe
Inlet nominal pipe size: DN 100
Outlet nominal pipe size: DN 100
Internal pipe diameter: Di = 107.1 mm = 0.1071 m
Pipe wall thickness: tp = 3.6 mm = 0.0036 m
Speed of sound in pipe: Cp = 5000 m/s
Density of pipe material: ρp = 7800 kg/m3
Other
Speed of sound in air: C0 = 343 m/s
Density of air: ρ0 = 1.293 kg/m3

Medium: Water Example 1 Example 2 Example 3
Mass flow rate ṁ = 30 kg/s ṁ = 40 kg/s ṁ = 40 kg/s
Valve inlet
p1 = 10 bar = 1.0 ∙ 106 Pa p1 = 10 bar = 1.0 ∙106 Pa p1 = 10 bar = 1.0 ∙ 106 Pa
absolute pressure
Valve outlet
p2 = 8 bar = 8.0 ∙ 105 Pa p2 = 6.5 bar = 6.5 ∙ 105 Pa p2 = 6.5 bar = 6.5 ∙ 105 Pa
absolute pressure
Vapor pressure of
pv = 2.32 ∙ 103 Pa pv = 2.32 ∙ 103 Pa pv = 2.32 ∙ 103 Pa
liquid
Density of liquid ρL = 997 kg/m³ ρL = 997 kg/m³ ρL = 997 kg/m³
Speed of sound in
cL = 1400 m/s cL = 1400 m/s cL = 1400 m/s
liquid
Table 18.4.-2: Example 1 to 3
Final results
Example 1 Example 2 Example 3
LpAe,1m = 62.7 dBA LpAe,1m = 81.0 dBA LpAe,1m = 66.9 dBA
Table 18.4.-3: Final results for LpAe of example 1 to 3
Figure 18.4.-4: Example 3 shows the influence of the xFz value on prediction accuracy.
Example 3 is identical with example 2, but the xFz value was shifted with 0.1.
This leads a significant prediction error of 66.9- 81 = -14.1 dB.
Hence, calculations of hydrodynamic noise based on eq. (8-74a) can create

uncertainties because it is only a rough estimation.
With xFz values measured by hydraulic test accuracy can be improved.

Figure 18.4.-5: Data Input from Example 1, 2, and 3


Item no. Example 1 Tag no. IEC 60534 8-4


Flow W [kg/s] 30 40 40
Outlet pressure p2 [bar(a)] 8 6,5 6,5
Density rho1 [kg/m³] 997 997 997
Vapor pressure pv [bar(a)] 0.0232 0.0232 0.0232
Critical pressure pc [bar(a)] 221 221 221
Viscosity eta [mPas] 1.00 1.00 1.00
Results and factors

Valve coeff. calculated Cv 88.4 89.1 89.1
Min. req. size Req. DN [mm] 87.5 101 101
Outlet velocity w [m/s] 3.83 5.11 5.11
SPL (EN 534 8-4) LA [dB(A)] 63 82 82
Different. pressure ratio xF 0.20 0.35 0.35
FL value FL 0.92 0.92 0.92
xFmr value xFmr 0.70 0.70 0.70
xFz value at load xFzp1 0.23 0.23 0.23
Valve data
Pressure ratings PN 40 Noise reduction without
Stem diameter Sd [mm] 16 Balanced without (0.0)
Internal parts material 4404 / 316L Leakage rate IV
Packing PTFE (1.6) Bonnet standard
Sealing metal (2.0)
cR [m/s] 5000 rho [kg/m³] 7800 di [mm] 107.1 s [mm] 3.6
Actuator data
Supply psu [bar] 3.80
(Defaults: p1max [bar(a)] 10 p2min [bar(a)] 1.01 t1max [°C] 20)
Actuator results


Item no. Example 1 Tag no. IEC 60534 8-4

More calculation data
Flow rate Case 1 Case 2 Case 3

Piping geometry factor FP [-] 1 1 1
Reynolds num. factor FR [-] 1 1 1
Valve Reynolds num. ReV [-] 3.8711E5 5.1448E5 5.1448E5
SPL calculation acc. EN 60534 P.8-4

Differential pressure ratio xF [-] 0.20 0.35 0.35
xFz value at load y and pressure p1 xFzp1 [-] 0.23 0.23 0.23
xFz value at load y and p_referencexFz [-] 0.23 0.23 0.23
Internal sound pressure level Lpi [dB] 150 157 157

Int. sound pres. level range 0.5-8kHzLpi(0.5-8kHz) [dB] 148 157 157
Outer sound pres. level range 0.5-8kHz
Lpa(0.5-8kHz) [dB] 66 83 83
Sound pressure level (1m) LpAa [dB(A)] 63 82 82
Acoustic conv. coeff. eta [dB] -58 -55 -55
Peak frequency (turbulence) fp,turb [Hz] 521 695 695
Peak frequency (Cavitation) fp,cav [Hz] 4891 1053 1053
Frequency division
Internal sound pressure level Lpi (octave bands)
31.5 Hz [dB] 134 138 138
63 Hz [dB] 137 141 141
125 Hz [dB] 140 145 145
250 Hz [dB] 143 148 148
500 Hz [dB] 145 151 151
1000 Hz [dB] 143 152 152
2000 Hz [dB] 135 151 151
4000 Hz [dB] 126 147 147
8000 Hz [dB] 117 143 143
16000 Hz [dB] 108 138 138
Sound pressure level (1m distance) Lpa (octave bands)
31.5 Hz [dB] 24 28 28
63 Hz [dB] 33 37 37
125 Hz [dB] 42 46 46
250 Hz [dB] 51 55 55
500 Hz [dB] 59 64 64
1000 Hz [dB] 62 72 72
2000 Hz [dB] 60 76 76
4000 Hz [dB] 57 78 78
8000 Hz [dB] 53 78 78
16000 Hz [dB] 45 75 75
Figure 18.4.-6: SAMSON Valve Sizing example 18.4

Detail calculation from SAMSON SVSS Example 1, 2, and 3.
In comparison to the original standard IEC 60534 8-4 Second Edition 2005-08 small
deviations occurs by the approximation of Cv = 90, which here are calculated correctly
with small differences to Cv = 90.

18.5 Calculation of stroking times (integrated in SAMSON Valve Sizing)

The dynamic behavior of a pneumatic actuator is influenced by the thermodynamic
processes in the diaphragm chamber volume and by the flow capacity of the accessory
(positioner, solenoid valve, etc.). The air supply network pressure pNV also plays an
important role.
Status changes in the diaphragm chamber space with the valve-setting-dependent volume
VA (H) usually proceed so that they approach isothermally (T = TA = const.). The signal
pressure pST is present in the volume VA. For this reason, air mass changes within the
volume due to ventilation or release of air are proportional to the change in the product of
pST (absolute pressure) and VA.
d
V A ⋅ pST + VA ⋅ pST= m
 ACC ⋅ Rair ⋅ TA with
dt
The actuator volume VA for fail-safe is dependent on the valve setting H in the following
way:
VA= V0 + A ∙ H (air to open)
VA (H) = V0+A∙(Hnom - H) (air to close)
V0 is the dead volume dependent on the actuator size A.
The mass flow can be determined using the DIN IEC 534 calculation equations for sizing
flow capacity.
 acc = Cvacc ⋅ 0.862 ⋅ Yexp ⋅ x acc ⋅

ρ0 ⋅ ρn Tn
m ⋅ ⋅p
∆ p0 ⋅ pn TA 1acc
pNV − pST
Venting air x acc = p1acc = pNV
pNV
pST − patm
Exhausting air x acc = p1acc = pST
pST
x acc
Expansion factor Yexp = 1 − xacc ≤ xxcrit.
3 ⋅ x acc
PN = 1.293 kg/m3; pN = 1.0132 bar; TN = 293.15 K

Air data / Norm
data ρ
Rair =N
⋅ TN ρ0 =
1000kg / m3 ; ∆ p =
1bar
pN
Table 18.5.-1: The mass flow can be determined using the DIN IEC 60534 calculation equations for
sizing flow capacity. Factors used in the equation above

Calculation of stroking times (integrated in SAMSON Valve Sizing) Page 047 of 050
Two differential equations are obtained from these equations which can be solved for
Cvacc = const. and p1 as well as p2 = const. during signal pressure change. If this is not
the case (e.g. due to the pump characteristic), only incremental calculation in small time
increments is possible. The first variant is implemented in the valve sizing program to
estimate opening and closing times.
The true representation (of the positioner, for example) is not possible in this way, i.e.
the times determined are usually smaller because in reality the positioner air capacity is
reduced as the regulator deviation reduces.
Specifying the mathematical equation of the closed solution would go too far at this point.
The following times are the result:
tO1 and tO2 for valve opening
tC1 and tC2 for valve closing
Figure 18.5.-2: Graphics from SAMSON SIZING
Typical values for Cv (Kv) attachment devices

Inlet air Outlet air Inlet air Outlet air
Cv ∙ 0.682 m /h Cv ∙ 0.682 m3/h
3 xT - value xT - value
Positioner 3766 0.081 0.127 0.7 0.7
Positioner 4765 0.081 0.081 0.7 0.7
Positioner 3780/3785 0.092 0.152 0.7 0.7
Positioner 3760 0.045 0.045 0.7 0.7
Solenoid Valve 3701 0.220 0.220 0.7 0.7
Catalog, Catalog,
Other solenoid valves 0.7 0.7
database database
Fair child 20 booster 0.531 0.531 0.7 0.7
Fair child 4500 booster 1.968 1.968 0.7 0.7
Table 18.5.-3: Typical values for Cv (Kv) attachment devices

18.5.1. Pipeline influence

The piping influence can also be determined in the valve sizing program.
(For fully-formed pipe roughness flow, (k = 0.03 mm run pipes))
π 2⋅ ∆p Dpipe5
Cvpipe ⋅ 0.862 =⋅ ⋅
4 ρ0 λ ⋅ Lpipe
Equation from Nikuradse1
1
λ= 2
 Dpipe 
 2 ⋅ lg + 174 
 2⋅k 
1
C=
vtotal Cvacc ⋅ 2
C 
1 +  vacc 
 Cvpipe 
Dead volumes
Actuation surface Dead volume Actuator rated travel
A cm2 V0 nom cm3 Hnom acc mm
80 130 15
240 425 15
350 690 15
700 2665 30
1400 6195 60
2100 12000 120
2800 20000 120

Table 18.5.-2: Dead volumes
V0 =V0nom. + (Hnom. acc − Hnom. valve ) ⋅ A
1 Johann Nikuradse a German engineer and physicist.

Nikuradse carefully measured the friction a turbulent fluid experiences as it flows down a rough pipe. He used
grains of sand of different roughness and discovered that the rougher the surface, the greater the friction, and
hence pressure loss.

Calculation of stroking times (integrated in SAMSON Valve Sizing) Page 049 of 050


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Table of contents

18. Calculation examples

18.1.1.1 Calculation of Cv-value, selection of valve characteristic and

18.1.1.5 Critical cavitation for globe valves is defined in SAMSON

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

18.2.1.1 Calculation of the flow coefficient (Cv-value). selection of the

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

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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

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

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

18. Calculation examples

Description Minimum Normal Maximum Unit

When inserting this figure into equation (5-9) we get:

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

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

Valve type xFmr ≈ xFid ≈ Kc ΔpCav.crit [bar]

1 Kiesbauer. J.: Control Valves for Critical Applications in Refineries.

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

Critical cavitation Hardening required Cavitation sound

18.1.1.4 Cavitation sound means:

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

Sound cavitation for globe valves is defined in SAMSON sizing:

Hardening required means:

18.1.1.5 Critical cavitation for globe valves is defined in SAMSON sizing:

AC-1 Trim AC-2 Trim* AC-3 Trim AC-5 Trim

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

Figure 18.1.1.5.-2: AC-2 Trim* Figure 18.1.1.5.-3: Additional baffles

Description Minimum Normal Maximum Unit

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

SAMSON SVSS calculates for PVC 4711

a) Plant characteristic b) Installed flow characteristic

d) Cv characteristic Type 3251

18.1.1.6 Valve selection flowchart

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

Yes ∆p > x1 AND xF > x4 Yes

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

High sound, damage and stress prevention

Standard Globe Rotary plug Butterfly / Ball

To avoid piping noise and vibration

4 Critical cavitation Risk of damage, keep U2* < 3 m/s

5 Incipient- or sound cavitation Risk of damage, keep U2* < 5 m/s

Table 18.1.1.6.-2: Legend and indices to Figure 18.1.1.6.-1 SAMSON sizing

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

18.1.1.7 Actuator calculation

Closing force FSF

Packing friction FR with a braided PTFE-Packing

Weight force FM here negligible.

Required actuator thrust

Required diaphragm area and actuator type

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

Figure 18.1.1.7.-1: Pressing "Result valve"

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

18.2.1.3 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

18.3.1.1 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