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:

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 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

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 Calculation and selection of a control valve for liquids Page 003 of 050

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

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 Page 004 of 050 Chapter 18.  Calculation examples

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.

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 Calculation and selection of a control valve for liquids Page 005 of 050

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.

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 Page 006 of 050 Chapter 18.  Calculation examples

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)

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

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.

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 Calculation and selection of a control valve for liquids Page 007 of 050

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).

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 Page 008 of 050 Chapter 18.  Calculation examples

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)

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 Calculation and selection of a control valve for liquids Page 009 of 050

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)

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 Calculation and selection of a control valve for liquids Page 013 of 050

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)

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 Page 014 of 050 Chapter 18.  Calculation examples

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.

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 Calculation and selection of a control valve for liquids Page 015 of 050

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

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Phone: +49 69 4009-0 · Fax: +49 69 4009-1507 · E-mail: [email protected] · Internet: www.samson.de
 Page 016 of 050 Chapter 18.  Calculation examples

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:

Description Minimum Normal Maximum Unit

Flow 8000 15000 20000 kg/h
Inlet pressure 30.0 22.0 16.0 bar
Outlet pressure 6.0 6.0 6.0 bar
Temperature 275 275 275 °C
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

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 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.

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

Phone: +49 69 4009-0 · Fax: +49 69 4009-1507 · E-mail: [email protected] · Internet: www.samson.de