. L + Highly erosive fuids, such as those carrying suspended solids or slurries, may require full prt valves which do not provide any obstruction to flow in the full open position. Never specify buttery valves for such services. ‘+ Ifthe flow stream contains fibrous particles, it may block or plug the valve openings. Diamond port plug valves, V-plug and V-ball valves have port shapes that minimize lugging. + Highly viscous or gummy fluids create a high pressure drop through valves and Piping. Ball valves, diaphragm valves and butterfly valves are ideal for these services. _ Service requirements: ‘Ask te following questions: * ‘Should the valve merely start and stop the flow? ‘+ Should it regulate (throttle) flow within @ preset flow range limit? ‘+ Should it provide a combination of two functions above? ‘+ How much through valve leakage can the system tolerate? Gate valves will provide tight shutoff but should not be used to regulate flow. Many inexpensive control valves will provide trotting but may not provide shut-ight, eg, buttery valves can provide excellent flow contol, but may not be bubble tight. tis often not possible to achieve operational needs wit a single, standard, off-the-shelf valve. A custom-built valve, or two standard valves in series, may often be required to obiain the desired results. Pressure - Temperature Rating (P-T Rating): ‘Ask the following questions: ‘+ What is the maximum pressure that the valve needs to be rated for? ‘+ What are the upstream and downstream pressures for each of the maximum, normal and minimum flow rates? + Is the valve operating consistently near the system's maximum design pressure and temperature? Scanned with CamScanner+ Do the system's peak pressure and temperature occur simultaneously? Do these conditions peak out only when the valve is open? These questions would decide the type of valve and its seating material. Here, we need to make distinction between “line pressure v/s valve pressure drop’. Often th misunderstood. The valve pressure envelope (valve body) is ‘subjected to the full line pressure (valve upstream pressure), whereas the pressure drop (AP) is the difference between the valve upstream pressure and the pressure that exists just downstream of the /e. The line pressure valve. Both pressures are equally important when selecting a control valv determines the valve body (and pipe flange) rating, whereas the pressure drop determines the valve trim or seat rating. The pressure-temperature rating of a valve is simply the maximum pressure the valve is designed to handle at a particular temperature and varies with the material of construction. The higher the process temperature, the less pressure can be handled by the body sub- assembly. \Valve's pressure rating describes the range of pressures a valve can handle - the higher the rating, the thicker the walls of the valve vessel to prevent rupture. The standard ANSI ratings are: 150, 300, 600, 900 etc. ANSI 150 rating valve does not mean that the maximum pressure rating of this valve is only 150 psi; a steel valve that is rated as ANSI class 150 can handle pressures up to 285 psi at 100°F (refer to the chart below). Scanned with CamScanner‘TEMPERATURE °C PRESSURE—Psi Source: ANSI 816.34 Materials of construction: General Service valves are specified with commonly found materials to match the pipe material. The standard materials are: * Carbon Stee! * Stainless Stee! + Chrome-moly For special services, the construction is offen guided primarily by the type of fluid, service temperature, etc, Here are few examples: * Concentration of the material inthe fluid is very important. Most chemicals are easier to handle in dilute concentrations, However, acids—such as sulfuric acid—become Scanned with CamScannermore aggressive as they are diluted with water. Some organic materials that are not corrosive by themselves become so in the presence of water. portant factor in choice of materials because high temperature © Temperature is ar increases corrosion. In addition, at very elevated temperatures, the pressure rating of the valve can be severely lowered due to deterioration of elther metallic or non- metallic material properties. Materials used in valves in hydrocarbon service experience sulfide stress cracking NACE standard MR-01-75 provides specific guidelines for their selection criteria Cast carbon steel (ASTM A216 - Grade WCB) is the most popular steel for valve ‘odies in moderate service such as air, superheat or saturated steam, non-corrosive fluids. Cast chrome-moly steel (ASTM A217 - Grade WCB-C9) has addition of chromium/Molybdenum that provide corrosion resistance and also suitable for temperature up to 1050°F. Cast type 304 SST (ASTM A351 - Grade CF8) Is for oxidizing and very corrosive fluids. same as 304 SST but since it has Cast type 316 SST (ASTM A351 - Grade CF8M) addition of Molybdenum it has better resistance to corrosion. «Cast Iron (ASTM A126) is used for steam, water, gas and non-corrosive fluids and is inexpensive. Cast Bronze (ASTM B61 and B62) is used for steam, air, water, oll and non-corrosive fluids. ‘Also ask this question: Does the valve stay closed (or open) most of the time? Many materials exhibit different corrosion characteristics in stagnant versus flowing conditions. A ‘int is Monel - a nickel-copper alloy. Monel is extremely well-suited to handling brine case in p in flowing conditions, but is a poor choice in stagnant conditions (Inconel would be @ better choice). Scanned with CamScannerValve Action: Valve action defines whether the valve will be fully open, or fully closed in the event of any process failure. The engineer must define whether the safest condition for each valve is fully ‘open or fully closed. This will be the failure position, and the combination of the actuator and valve body must achieve this position upon loss of power. We must analyze the entire process, including integrated units to identiy the safest conditions. In a few cases, the failure condition is “unchanged”. If the air power is lost, air leakage will result in a slow drift to either open or closed. Let's take an example: If the valve is used to control steam or fuel flow, the valve should be shut off completely. On the other hand, if the valve is handling cooling water to a reactor, the flow should be maximum in case of emergency. Control valves operated through pneumatic actuators can be either (i) air to open, or (i) air to close. If all the power goes out or some other emergency occurs, the decision on the fail-safe mode of the valve is a huge factor in saving lives. Valve Size (Capacity): Valves are sized according to their Cv value. For liquid service, the equation for Cv is: ov =a (S75) The required flow and pressure drop information used to size a valve is based on the process operations and equipment. Once the Cv value is known, the rated" Cv can be determined from the manufacturer's data books. A general guideline is that valves should be sized so that maximum flow is obtained at about 90% valve open. Valves should be able to provide normal flow condition at around 60% to 70% of the travel. Valve should provide minimum flow when about 10% open. The control valve need not be of the same size as the pipe. It is better to make an error in under sizing a control valve than to oversize it. ‘As a good engineering practice, the rated Cv of the valve shall be in accordance with following criteria: Ifnormal flow is specified: Calculated Cv - Based on the normal flow Selected Cv - Based on 1.4 x normal flow Scanned with CamScannerfmaximum flow is specified but is equal to or less t al ‘* Calculated Cv ~ based on normal flow Selected Cv ~ based on 1.5 x normal flow than 1,4 x normal flow ‘When maximum J * Calculated Cv — Based on normal flow Selected Cv — Based on 1.1 x maximum flow Precise system control: ‘Some system control loops require highly accurate control in the face of severe disturbances. pattern. Ideally the control valve should have low friction, no backlash, and a stable flow Rotary valves, such as high-performance butterfly and plug valves employing low- friction bearings and packings provide good control. Ball valves have large backiash and are not recommended. Linear motion valves, such as globe valves cannot match the low friction of rotary valves and must be critically evaluated. Leakage or Tight shut-o will have virtually no flow or leakage in its closed position, A valve having tight shutoff nly single-seated valves have tight shutoff. Double-seated valves may Generally speaking, 01 be expected to have a leakage of 2 to 5% while in closed position. Control valve seat leakage shall be designed and constructed in accordance with the requirements to ANSI B 16-104. * Class 1-N/A Class Il - 0.5% of maximum valve capacity Class Ill - 0.1% of maximum valve capacity Class IV - 0.01% of maximum valve capacity Class V - 0,0005 mi/min/inch of port dia./psi differential Scanned with CamScannerClose-off pressure is an important parameter that defines the differential pressure requires 10 seat the valve and stop flow completely and is a function of the hydraulic design of the system and the criteria for deciding the type of valve actuator. Typically, actuators are either clectronic or pneumatic. The significant performance differentiator between the two is speed of operation. While the electric actuators are better known for their high tevels of precision: the pneumatic actuators are very popular due to their relatively low cost, high power output, and relabilly. The choice of pneumatic or electic actuators involves an evaluation of performance, component costs, system costs, and productity gains. Each has inherent advantages and disadvantages, Refer to Section 1 for a detailed comparison off” and wil likely to be ic control valves are not designed to produce “tight shu ‘sed, Consequently, most contro! valve ‘Note- Automal .5 which can be turned when complete prone to small amount of leakage when clo installations include block valves or manual valves shutoff is needed. CONTROL VALVE SIZING EQUATIONS In order to determine the correct size of a valve for a specific system, many factors must be considered, The most important factor fs the capacity parameter, Cv, oF the flow coefficient. -To determine the valve size needed for your system, you can estimate Cv with the following ‘equations: ui their flow rate depends only on the difference Because liquids are incompressible fluids, ure drop). The flow is the same whether the (AP, press between the inlet and outlet pressures the difference between the inlet and outlet system pressure is low or high, so long as pressure is the same. The equation below shows the relationship: cv = a/(S75P) Where, «© Cv= Valve flow coefficient, US GPM with P= 1 psi © Q= Fluid flow, US GPM $= Specific gravity of fluid relative to water @ 60F ‘AP = Pressure drop (P; Pz) at maximum flow, psi Scanned with CamScanner‘Specific gravity correction is negligible for water below 200°F (use S = 1.0). Use actual specific gravity S of other liquids at actual flow temperature. Use the following equation for fluids with viscosity correction factor. Use actual specific gravity $ for fluids at actual flow temperature. cv=KQ (SIP) Where, + K= Viscosity correction factor for fuids pe: dian stimat ‘Another important piece of information about sizing and specifications is what diameter pipe may be used with a certain flow, seen in the following equation: Where: d= diameter of pipe (ft) © Qmur= maximum flow through the valve (f'/s) + v= velocity of flow (ft/s) Airand Gaseous Flow (natural gas, propane etc. as flow calculations are slightly more complex because gases are compressible fluids whose density changes with pressure. In addition, there are two conditions that must be considered: low pressure drop flow and high pressure drop flow. Use the following equation when outlet pressure (P,) is greater than one half of inlet pressure Po. Qa/G (T + 460) cvs ————— 1360 /P(P2) Use the following equation when outlet pressure (P,)_is less than or equal to % of inlet pressure (Py Scanned with CamScanner0/6 (Fa) ‘660 P, Where, Cv= Valve flow coefficient, US GPM with P = 1 psi Qa = Airor gas fow, standard cubic feet per hour (SCFH) at 4.7 psig and 60F T= Flowing air or gas temperature (F) AP = Pressure drop (P1 ~ P2) at maximum flow, psi P, = Outlet pressure at maximum flow, psia (abs.) in % +P; = Inlet pressure at maximum flow, psia (abs.) ressure ‘When the outlet pressure is less than drop. The gas will behave differently ry to use the correct equation is important, as seen above, ‘The relationship between the inlet and outlet pr determining which equation to use for gaseous flow. the inlet pressure, this is said to be a critical pressure when the pressure drop is critical; therefore It is necessa depending on the extent of pressure drop. Once you have computed the desired value of Cy you can choose the valve. The chosen valve must have & valve coefficient greater than or equal to the computed value. For Steam (saturated or superheated): ise the following equation when P2 is areater than % P; wk 2.1VaP(P +) Use the following equation when P; is less than or equal to % Py ove WK 1.82P, Where, * Cv= Valve flow coefficient, US GPM with P = 1 psi Scanned with CamScanner