Control Valves in Process Plant
Control Valves in Process Plant
Control Valves in Process Plant
ControIValve.s,
In
Process Plan
For proper performance in any piping 'system, he e are the design relations, sizing
formulas and installation procedures for seleCting and using control valves for fluids.
CE REFRESHER
, \
Single-Seat (Equal-percentage
contoured plug, fails closed)
Double-Seat (Equal-percentage
ported plug, fails open)'
Alternative
Actuator and Plugs
CONTROL valves handle many types of process fluids. and are actuated by air In response to a process signal-Fig. 1
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Butterfly
Valve
Ball Valve
Camflex Valve
Safety Requirements
Without air pressure in the pneumatic actuator, the
valve can be in clos~dor open position. These alternative
86
ROTARY actuator
moves flap, plug
or disk-Fig. 3
APRIL 14, 1975/CHEMICAL ENGINEERING
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Lubricator for
valve-stem
packing box
Bellows Bonnet
(Seal between valve and
packing box in toxic service)
Extension Bonnet
(For cryogenic temperatures)
Finned Bonnet
0
(For temperatures higher than 400 F) .
Side Mounted
Case Mounted
Pneumatic Positioner
(Or transmitter) .
Handwheels
(For manual operation at
startup or air failure)
limit Stop
(Restricts stem movement!
ACCESSORIES extend usefulness of control valves by providing for extreme and unusual conditions-Fig. 2
87
CE REFRESHER
I
Nomenclature
C,
Crr
C"
==
Q( VS/y"M)
This is an optimum range for lirtear and percentagecontoured plugs. Some valves have a wider optimum
range. All valves will operate below and above these
Cve/Cv ratios, but the plug willl:>~ closer to the fully open
or fully closed position. Under these conditions, we lose
the important advantage of having wide flexibility in '
controllable flow-capacity range, and this may limit,
operability of the process.
High velocities across' the valve orifice can wear out
the plug and seat, especially if temperature is also high
or when abrasive fluid is present.
Critical Flow Factor, C,-The pressure gradient across
a control valve is shown in Fig. 5. For liquids, the flow
can be considered subcritical if the vapor pressure of the
liquid will not get higher than the lowest pressure'point
across the control valve. (Vapor pressure is the pressure
at which the liquid begins to vaporize at its flowing
temperature. Tables of thermodynamic properties of liquids give corresponding saturated-liquid pressures and
temperatures.)
If the vapor pressure falls between the ranges of A
and B (see Fig. 5), vaporization or cavitation will occur
88
II
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(/)
c,z(t:,.p.)
(2)
t:..P
where:
t:,.p. == PI
a. 5PI
(3)
<
==
(Q/Cr)(VS/..;t;P.)
(4)
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!
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Single-Seat"
Double-Seat"
v. = 68Vk(~'/p), ft/~.
(5)
.0/.
12
1%
14
18
1%
21
28
36
48
t:,p
< 0.5C,zPl
(6)
2%
54
72
t::.P ~ O.5Q Pl
(7)
75 .
110
124
195
270
450
480
750
10
750
1,160
12
1,080
1,620
14
1,470
2,000
16
1,920
2,560
Liquid Service
Suberitical Flow-For a liquid flowing well below its
saturation temperature in the turbulent zone, wjth vis~
cosity close to that of water, and sizes of the pipe and
control valve identical, the' calculated control-valve
coefficient is:
(8)
(9)
J '.
t:,p =
Q
J2
[ (C"jC")C,, S,psi
(10)
CE REFRESHER
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Condition
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Double-Seat*
Single-Seat*
Factor
Equal-Percentage
V-Port
Equal-Percentage
V-Port
Cr
0.98 t or 0.85*
0.98
0.90
0.98
Crr
0.86
0.94
0.86
0.94
Critical flow
Line size control valve
1------
Critical flow
(Control valve between
pipe reducers) .
f-----'----
R
R
0.96
0.94
''-._-_.-
, These values have been obtained for Masoneilan 10.000-series plug valves having fUII:capacity trim. but also apply to similar valves of other manufacturers [2].
'Faclor for flow 10 open.
'Factor for flow to close.
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=:::
(QICr)( VSivi\
PII )
C =
W_
'!C
63.3 '1[6;1'1'1
::':;
W
11.65 V3P(P1
P2)Pl
-----~--==
where ::"1'
1\ - 1'2' provided th.at t::,p
For critical flow when ::'1' ~ O.SC/pt :
.
>
.rently (i.e., Pv
PI)' additional vaporization of
liquid can be assumed inside the control valve. For this
condition:
C vr = 1O.13C'p1 V;;;
(13)
< n.5C/p!.
(14)
Two-Phase Flow
For well-mixed liquid and inert gas in turbulent flow
with no additional vaporization, the following applies:
w
c,,,. = 44.8 Y'X/>(=(IJ=+='='z==)-
(15)
where PI and P2 are the upstream and downstream two'phase densities, respectively.
When saturated liquid enters the valve (i.e., PI == Pv ),
or saturated liquid and its saturated vapor flow concur90
CE REFRESHER .
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'"c
:i:
c
..,
<V
No. 556
No. 576P
No. 1040
No. 1042
No. 1046
Flow Coefficient,
Cv
Size,
In
For Valves
No. 546P-150 Psi
No. 556P-200 Psi
No. 576P300 Psi
Flow Coefficient,
Flow Coefficient,
Cv
For Valves
No. 556-200 Psi
No. 576300 Psi
Flow Coefficient,
Cv
Size,
In
For Valve
No. 1040-150 Psi
Cv
For Valves
No. 1042-300 Psi
No. 1046-600 Psi
0.9
1.2
46
55
4.2
2~
72
90
8.6
105
130
10
14.5
200
235
1~
24.
29.5
. 400
400
41
49
720
720
Note: Flow coefficients have been obtained for valves manufactured by Jenkins
Bros. but also apply to similar valves of other manufactu,rers.
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~~[><]TcklfG) "
)c,
4'"
' _d"l
~r..,"';=.".".,.. _"-".,.,.,"",""..."-,....,,7"1
T
..:;
'0~?
MANIFOLDS and bypasses for installing control valves into the process piping require proper clearances and drains-Fig. 7
tion system. Sensing points for flow, pressure, temperature and level should be close to the control valve, as
shoul~ the. transmitter. Instrument' wiring and tubing
connect these elements. Air lines run from the transmitter
to the diaphragm housing, and from the transmitter to
.the, instrument-air header.
Level controllers usually have gage-glass companions.
It is convenient for the plant operator to see the gage
glasses from the control-valve manifold when operating
the control-valve handwheel or the bypass globe valve.
The next article in this series will appear in the issue
of Apr. 28, 1975, and will cover the design relations for
sizing pump-suction piping. #
References
I. "Handbook for Control Valve Sizing," Masoneilan International, Inc.
Norwood, MA 02062.
2. Dimensions-Masoneilan Control Valves and Auxiliary Equipment,
Masoneilan International, Inc., Norwood, MA 02062.
3. "Valve Sizing," Catalog 10, Fisher Controls Co., Marshalltown, IA
50158.
4. Fisher Control Valve Dimensions, Bulletin 1-100, Fisher Controls
Co., Marshalltown, IA 50158.
5. Boger, H.W., Recent Trends in Sizing Control Valves, 23rd Annual
Symposium on Instrumentation for the Process Industries, Texas
. A&M University, College Station, TX 77843, 1968.
6. Baumann, H. D., The Introduction of Critical Flow Factor for Valve
Sizing,ISA (Instr. Soc. Am.) Trans., Apr. 1963.
7. Baumann, H. D., Effect of Pipe Reducers on Valve Capacity, Instr.
Control Systems, Dec. 1967.
. 8. Boger, H. W., Sizing Control Valves for Flashing Service, Instr.
Control Systems, Jan. 1970.
9. Boger; H. W., Flow Characteristics for Control Valve Installations,
ISA (Instr. Soc. Am) 1., Oct. 1966.
10. Hutchison, J. W. (Ed.), "ISA Handbook of Control Valves,',' Instrument Soc. of America, Pittsburgh, 1971.
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