Control Valve Optimization by

CONVAL

Hadi Veyse – Oil and Gas Operation Superintendent

Static Controllability index - Ci

At ACHEMA 2009, F.I.R.S.T. GmbH introduced the Controllability index Ci, a Key Performance
Indicator (KPI) for the static controllability of a control valve application.

A static index helping you to better optimize your valve configuration during the sizing and selection
process. The index is derived from comparing the ideal gain of the controlled variable with the actual
gain.

One can have an index for flow control, upstream pressure control, downstream pressure control
and/or differential pressure control. One can have an index for follow up control (full range or
working range), set point control (high capacity) and/or start-up control (low capacity).

The theoretical ideal gain for flow control has an index of 0. For all practical purposes the index is a
value between 0 (good) and 2 (to be improved).

A Controllability index calculated as:

Reliability index - Ri

At Valve World Expo 2012, the Reliability index Ri is released, another Key Performance Indicator
(KPI), describing the overall reliability of a control valve application.

The Ri system is based on decades of experience, failure root analysis, as well as feedback from
customers and valve manufacturers and their publications. Whenever possible the system leans on
actual standards and regulations. It should be understood as an open system, not perfect for any
case of trouble. If in doubt, your valve expert as well as your manufacturer should be involved
because of their major responsibility.

At the other hand valve failures are ever possible. If they are not detected from the Ri system,
means the system Ri weight factors are not fine-tuned enough or don't fit for any valve quality in
this time. In all cases of good or bad reliability prediction any feedback to the CONVAL
team is welcome!

Most important to know: The Ri system is based on ideal fluid and material conditions. That means
the material quality must avoid any fluid corrosion. Hardening qualities give the optimum protection
to fluid abrasion, dirt and slurries and need also to withstand possible fluid corrosion attacks. In case
of standard material the Ri system can handle only non-corrosive and non-abrasive fluids.
Reliability index - Ri

The meaning of the numerical values of Ri is:

Influence factors on the Reliability index for gases:

• Outlet/piping
• Power loss
• High velocity
• Sound pressure level
• Seat tightness
• Less overheated

Influence factors on the Reliability index for liquids:

• Flashing
• High Velocity
• Seat tightness
• Sound pressure level
• Cavitation damage
• Actuator with globe valves FTC
Reliability index - Ri

Reliability subclasses diagram shows key reliability criteria to figure out where the root cause of the
problem is, the tool is offering a “Reliability subclasses” diagram, showing key reliability criteria
besides a map and a “set of graphs” window. Each subclass indicates which kind of valve solution is
suitable for the given data. When exploring the full working range of the valve, the “subclasses
window” indicates in which subclass the application is for a given working point as well as the key
reliability parameters, like the differential pressure over the valve, the outlet velocity, the sound
pressure level and the cavitation related parameters like xF, Kc, xFz. The “graphs window” shows
the Reliability index value, the reliability influencing variables and a recommendation for a valve
solution to mitigate the current reliability challenges.
Flow reserve - a

Flow reserve is the available flow capacity beyond the maximum operating point, expressed as the
ratio of flow at maximum valve open position divided by the flow at maximum operating point. It is
a direct function of the selected nominal flow coefficient. Parameter expression a = Q100/Q1.

Inadequate flow reserve has a significant potential controllability impact. Participants at the Valve
World 2008 controllability workshop rated it as the third most important controllability parameter to
observe.

Flow reserve a:
If 1.15 < a < 1.25 valve controllability is not impacted.
If a < 1.10 valve controllability is impacted.
If a < 1.05 valve controllability is significantly impacted.
Valve authority - va

Valve authority is the available differential pressure over the full working range. It is the ratio of the
valve differential pressure at a given working point divided by valve differential pressure at the
minimum controllable flow. The most challenging value is at the full open position Δp100/Δp0. It is a
given of the plant system dynamics. Inadequate valve authority has a negative effect on the
controllability. Valve authority is one of the most important controllability parameter to observe.

The selection of the control valve should be based on the design flow with its relevant process data.
Unless otherwise specified, the following should apply:

• The valve shall be sized for 110% of the design flow rate Qop1 in order to allow control at Qop1.
• The flow rate through a fully open control valve Q100 shall be equal to or greater than the
maximum controllable flow rate.
• To avoid excessive loop gain variations, the control Valve authority at design conditions vaop1
should be greater than 0.27.

The valve nominal Cv shall not be oversized, to avoid on-off installed characteristic.
Valve authority - va

In order for control elements to actually be able to control at the operating point, plant designers
must take the differential pressure requirement of valves into account. A control valve can only
intervene in the process if it has sufficient authority:

• va = Δp100/Δp0 = 1
Highest authority. The complete differential pressure is relaxed at the valve. No drop in the pump
characteristic, no pressure losses in the pipe. This is however a theoretical value.
• 1 > va = Δp100/Δp0 > 0.3
Good authority, also with linear modified valve characteristics. This situation is comparatively rare,
too.
• 0.3 > va = Δp100/Δp0 > 0.1
Adequate authority by adjusting the valve characteristic in the equal-percentage direction. This is
the most common variant encountered in real systems.
• 0.1 > va = Δp100/Δp0 > 0.0
Restricted authority with loss of control quality. Common causes are cost and time pressures when
the plant is designed.

Rational plant design, which takes adequate account of the differential pressure requirement of
control elements, is essential in order to achieve maximum control quality at the operating point by
selecting the optimum Cv100 value.

Valve authority va:

If va> 0.23 valve controllability is not impacted.
If va< 0.15 valve controllability is significantly impacted.

Inadequate Valve authority has an equal significant potential controllability impact.

Valve authority - va

A red area below the Valve authority curve warns of control problems at maximum flow in the case
of:

Low flow reserve a: Qop1 > 0.9 Q100

Low Valve authority va: vaop1 < 0.23

In this case, the flow reserve and/or valve authority is too small. The flow reserve can be improved
by using a valve with a higher flow coefficient. An improvement in Valve authority requires a change
in the pressure ratio Δp of the plant system.
Gain ratio of loop - r

The control range for the flow rate and the valve opening in the region of an acceptable loop Gain
ratio r is indicated by means of a bar underneath the X-axes:

• Recommendation for uncritical controlled systems: r = 4 (Gain ratio of loop = 4, i.e. the loop gain
ratio over the full stable working range should be below 4, i.e. a gain between 0.5 and 2).
• Recommendation for critical controlled systems: r = 2 to r = 3.

A step response (transient function) provides an indication of the ordinal number and thus the
potential complexity of the system which must be controlled (loop). Non-time-critical, 1st or 2nd-
order controlled systems generally permit a Gain ratio in the region of 4:1. The ordinal number and
the tendency to hunt increase with the number of time-delay elements. A more constant installed
flow characteristic gain (2:1 or 3:1) is preferable for the control range in question with higher ordinal
numbers or very dynamic (fast-response) controlled systems. This is particularly true if the time
response of a pneumatic control loop approaches the time response for signal transfer. If the control
range in question is not covered by any ruler position, it is advisable to improve it by altering the
Cv100 value, the characteristic or the rangeability.
Thanks for your attention