Control Valve Process Sizing: Corporate Criteria

Doc. No.
CR-COR-ENG_PRC-005
CORPORATE CRITERIA
Rev. 01 Date 13/12/13
CONTROL VALVE PROCESS SIZING
Page 1 of 36
CORPORATE CRITERIA
CR-COR-ENG_PRC-005
13/12/13 01 First issue S. Ingrosso G. Poni A. Cipelli

OILGAS PROTEC ENG
Date Revision Description of Revision Prepared Checked Approved
This document is the property of Saipem S.p.A. All rights reserved
Summary of Revisions
Doc. No. CR-COR-ENG_PRC-005
CORPORATE CRITERIA
Rev. 01 Date 13/12/13
Page 2 of 36
13/12/13 01 First issue S. Ingrosso G. Poni A. Cipelli

OILGAS PROTEC ENG
Date Revision Description of Revision Prepared Checked Approved

CORPORATE CRITERIA
Rev. 01 Date 13/12/13
Page 3 of 36
INDEX
1 SCOPE AND PURPOSE 5

1.1 OBJECTIVE 5
2 REFERENCE DOCUMENTS 5
2.1 INTERNATIONAL STANDARDS 5
2.2 RECOMMENDED PRACTICES AND CRITERIA 5
2.3 SAIPEM REFERENCES 5
3 DEFINITIONS 6
3.1 TERMS 6
3.2 ACRONYMS 7
3.3 SYMBOLS 7
4 DESCRIPTION OF ACTIVITIES 8
4.1 DEFINITION OF THE CIRCUIT 9
4.2 DESIGN AND OPERATING CASES SPECIFICATION 9
4.2.1 Minimum pressure drop for control 12
4.2.2 Specific cases 12
4.3 FLOW COEFFICIENT PRELIMINARY CALCULATION 13
4.3.1 Gas and Vapours 14
4.3.2 Liquids 15
4.3.3 Two phases 17
4.3.4 Rangeability 17
4.4 ADDITIONAL REQUIREMENTS 18
4.4.1 Fail position 18
4.4.2 Maximum not controlled flow rate 19
4.4.3 On/off service 19
4.4.4 Mechanical stop 19
4.4.5 Maximum differential pressure on closed valve 19
4.4.6 Solenoid valve 20
4.4.7 Valve stroke time 20
4.4.8 Leakage classes 20
4.4.9 Limit switch 20
5 ATTACHMENTS 21
5.1 THEORY 21
5.1.1 Flow path and Vena Contracta 21
5.1.2 Inherent flow characteristics 22
5.1.3 Installed flow characteristics 23
5.1.4 Gain 24
5.1.5 Available stem travel 25
5.1.6 Direct and reverse actuators 25
5.1.7 Multi-stage control valves 25
5.2 VALVE TYPES 26
5.2.1 Globe valve 26
5.2.2 Needle valve 28
5.2.3 Diaphragm valve 28
5.2.4 Butterfly valve 29
5.2.5 Eccentric rotary plug valve 29
5.2.6 Ball valve 30
5.2.7 Axial valve 30
5.2.8 Summary table 31
5.3 LEAKAGE CLASSES 31
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5.4 EFFECT OF PIPE REDUCERS 32

5.4.1 Calculation of FP 32
5.4.2 Calculation of xTP 33
5.4.3 Calculation of FLP 33
5.5 CONTROL VALVE DATA SHEET 33
5.5.1 Typical notes 35
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1 SCOPE AND PURPOSE

The purpose of this Corporate Criteria is to define the design guidelines for control valves process sizing,
including valve flow coefficient preliminary estimation.
This Corporate Criteria applies to the engineering and construction projects of interest of the Saipem Group.
1.1 OBJECTIVE
The aim of this document is to define the process design rules for control valve specification and provide a
procedure for preliminary valve flow coefficient (C V) calculation; the CV calculation is only for preliminary
design activities and should be confirmed by instrument function.
In cases where the contract specifies that Client design criteria have to be applied, Saipem design rules
should be considered only as reference.
2 REFERENCE DOCUMENTS
2.1 INTERNATIONAL STANDARDS
ANSI/ISA–75.05.01 Control valve terminology
API STD 598 Valve inspection and testing
FCI-70-2 Fluid controls institute standard – Control valves seat leakage
IEC 60534-1 Control valve terminology and general considerations
IEC 60534-2-1 Industrial process control valves part 2-1 Flow capacity – Sizing equations for
fluid flow under installed conditions
IEC 60534-4 Industrial process control valves part 4 - Inspection and routine testing
2.2 RECOMMENDED PRACTICES AND CRITERIA

GPSA Engineering Data Book
2.3 SAIPEM REFERENCES

CR-COR-ENG_PRC-002 Process Pipe Sizing
CR-COR-ENG_PRC-008 Acoustic Fatigue Process Check
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3 DEFINITIONS
3.1 TERMS
Pneumatic, hydraulic, or electrically powered device that supplies force and
Actuator motion to position a valve’s closure member at or between the open or closed
position.
The main pressure boundary of the valve that also provides the pipe connecting
Body
ends and the fluid flow passageway, and supports the valve trim.
The portion of the valve that contains the packing box and stem seal and may
guide the stem. It provides the principal opening to the body cavity for assembly of
Bonnet
internal parts or it may be an integral part of the valve body. It may also provide for
the attachment of the actuator to the valve body.
A part of a valve trim, in a globe or angle body, that surrounds the closure member
and whose flow passages may provide flow characterization and / or a seating
Cage
surface. It may also provide stability, guiding, balance, and alignment, and
facilitate assembly of other parts of the valve trim.
A two-stage phenomenon of liquid flow. The first stage is the formation of vapour
bubbles within the liquid system due to static pressure of fluid falling below the
Cavitation fluid vapour pressure; the second stage is the collapse or implosion of these
cavities back into an all-liquid state as the fluid decelerates and static pressure is
recovered.
Control valve trim that provides a defined flow characteristics, such as equal
Characterized trim percentage, linear or quick opening, usually stated in terms of C V or KV versus
travel.
A condition wherein the flow rate through a restriction does not increase when the
Choked flow
downstream pressure is decreased at a fixed inlet pressure.
The movable part of the valve that is positioned in the flow path to modulate the
Closure member
rate of flow through the valve.
A control valve is a power operated device forming a final element in a process
Control valve
control system.
A circular shaped closure member used to modify the flow rate with either linear or
Disk
rotary motion.
A mechanical manual override device, using a rotary wheel, to stroke a valve or to
Hand-wheel
limit its travel.
Leakage class Classifications established by ANSI/FCI 70-2 to categorize seat leakage

allowances for different needs of seat tightness.
A sealing system consisting of deformable material contained in a packing box
Packing that usually has an adjustable compression means to obtain or maintain an
effective seal.
Plug A term frequently used to refer to the closure member.
The ratio of the largest flow coefficient (Cv or Kv) to the smallest controllable flow
Rangeability coefficient (Cv or Kv) within which the deviation from the specified flow
characteristic does not exceed the stated limits.
A part of the valve body assembly that provides a seating surface for the closure
Seat ring
member and may provide part of the flow control orifice.
Shaft The mechanical member used to support and move a rotary closure member.
The mechanical member, in a linear motion valve, that connects the actuator stem
Stem
with the closure member.
Trim The internal components of a valve that modulate the flow of the controlled fluid.
The portion of a flow stream where fluid velocity is at its maximum, while the fluid
static pressure and the cross sectional area are at their minimum. In a control
Vena contracta
valve, the vena contracta normally occurs just downstream of the actual physical
restriction.
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3.2 ACRONYMS
DCS Distributed Control System
ESD Emergency Shut-Down
FC Fail Close
FL Fail in Lock position
FLC Fail Last drift to Close
FLO Fail Last drift to Open
FO Fail Open
N/A Not Available
P&ID Piping and Instrumentation Diagram
TSO Tight Shut-Off
3.3 SYMBOLS
Symbol Definition Unit of measure
CV Valve flow coefficient Gallon/minute
CV partial Flow coefficient for a partially open control Gallon/minute
valve
dIN Inside diameter of upstream pipe mm
dOUT Inside diameter of downstream pipe mm
dV Valve end inside diameter mm
fg Weight fraction of gas in a two phases flow Dimensionless
fl Weight fraction of liquid in a two phases flow Dimensionless
g Gravity acceleration m/s2
FL Liquid pressure recovery factor Dimensionless
FLP Liquid pressure recovery factor with Dimensionless
attached fittings
F Ratio of specific heats factor Dimensionless
h Geometrical height m
K1 Inlet pipe reducer loss coefficient Dimensionless
K2 Outlet pipe reducer loss coefficient Dimensionless
KB1 Inlet pipe reducer Bernoulli coefficient Dimensionless
KB2 Outlet pipe reducer Bernoulli coefficient Dimensionless
KV Valve flow coefficient m3/h
MW Gas Molecular weight kg/kmol
Pc Critical pressure bar a
PDW Pressure at the pressure controlled point bar a
downstream of the control valve
PIN Pressure at control valve inlet bar a
POUT Pressure at control valve outlet bar a
PUP Pressure at the pressure controlled point bar a
upstream of the control valve
Pv Vapour pressure of the fluid bar a
PVC Pressure in the vena contracta bar a
Q Volumetric flow rate m3/h
R Ideal gas constant m3*bar/(kmol*K)
Ra Rangeability Dimensionless
RaP Process rangeability Dimensionless
T Temperature at inlet conditions °C
W Mass flow rate kg/h
x Pressure drop ratio Dimensionless
xchoked Pressure drop ratio for choked flow Dimensionless
xsizing Pressure drop ratio for valve sizing Dimensionless
xT Pressure differential ratio factor at choked Dimensionless
flow
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xTP Pressure differential ratio factor at choked Dimensionless

flow with attached fittings
Y Gas expansion factor Dimensionless
z Gas compressibility factor at inlet conditions Dimensionless
Greek letters
Symbol Definition Unit of measure

P Differential pressure bar
PIN Differential pressure due to pressure drop of bar
the inlet line and equipment
POUT Differential pressure due to pressure drop of bar
the outlet line and equipment
PPUMP Pump differential pressure bar
PSH,IN Differential pressure due static head in the bar
inlet line
PSH,OUT Differential pressure due static head in the bar
outlet line
 Density kg/m3
g Gas Density kg/m3
l Liquid Density kg/m3
4 DESCRIPTION OF ACTIVITIES
A control valve is a valve with a pneumatic, hydraulic, electric or other actuator (such as handwheel), that
opens or closes the valve, fully or partially.
The control valves are used to control operating conditions such as flow, pressure, temperature or liquid level
by opening or closing in response to signals received from controllers that compare a "set-point" to a
"process variable" whose value is provided by sensors that monitor changes in such conditions.
The following figure helps to understand the action of a control valve in determining the flow rate of a circuit
containing a centrifugal pump and a control valve. The control valve uses part of the head generated by the
pump in order to set the circuit flow rate.
Figure 1 – Control action in a pump / valve circuit
The process activities relevant to control valve include:

 Definition of the circuit.
 Design and operating cases specification.
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 Flow coefficient (CV) preliminary calculation (optional).

 Additional requirements definition.
4.1 DEFINITION OF THE CIRCUIT

In order to properly size a control valve, it is very important to identify and to deeply investigate the relevant
process circuit. The relevant process circuit is in-between the upstream controlled pressure point and the
downstream controlled pressure point. The two points may coincide (closed loop).
For each valve, a simplified hydraulic sketch of the process circuit should be developed, showing the
following:
 Simplified equipment layout, including tag, elevation, nozzle / pipe sizing, level quotes, etc.
 Piping arrangement including the sizes, schedules and elevations.
 Operating pressure values for the upstream and downstream controlled pressure points.
 Fittings: preliminary information is based on the P&ID with some assumptions (curves, etc.)
 Piping length: preliminary information is based on the P&ID and plot plan.
When final information based on 3D model or isometric drawings is available, each circuit is finalized
together with the relevant control valve data.
Figure 2 – Typical sketch of a control valve circuit
Inlet pipe length; D P=XXX Outlet pipe length DP=YYY

PV-2
PV-1
P2
Diameter
P1 V-002 Max level
Min level
V-001 Max level
Min level
D3" schedule ZZZ
D1" schedule XXX
Vessel elevation
Vessel elevation
E-001
Pump DPE2
DPPUM
Strainer D2" YYY
D PE1 P
P-001A
4.2 DESIGN AND OPERATING CASES SPECIFICATION

The information required for the control valve mechanical sizing is related to the maximum, normal and
minimum valve opening.
When the valve opening is maximum, the volume flow rate through the valve is maximum, and consequently
the available pressure drop across the valve is minimum. Similarly, when the valve opening is minimum, the
volume flow rate through the valve is minimum and consequently the available pressure drop across the
valve is maximum. The normal flow conditions are also required, when different from the maximum, as
normal operation could be the sizing case (e.g. for noise calculation), except for normally no flow lines.
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The valve inlet pressure is calculated with the following equation, where the single terms are better specified
in the following paragraphs.
Equation 1
P¿ =PUP +∆ PSH ,∈¿+∆ P PUMP −∆ P¿ ¿
The pressure increase due to static head is calculated with the following equation:
Equation 2
∆P ρ ∙ g ∙h
SH ,∈¿= ¿
105
Where  is the fluid density, g the gravity acceleration and h the liquid height.
The pressure increase due to pump (when applicable) is calculated with the following equation:
Equation 3
ρ∙ g ∙ H
∆ P PUMP=
10 5
Where  is the fluid density, g the gravity acceleration and H the pump head.
The valve outlet pressure is calculated with the following equation.
Equation 4
POUT =P DW −∆ PSH ,OUT + ∆ POUT
Maximum opening
Generally, the design case selection for control valve sizing is quite easy, considering a constant pressure at
both ends of the circuit. At the maximum volumetric flow rate usually corresponds the maximum pressure
drop upstream and downstream of the valve, and so the minimum pressure drop across the control valve.
This is not always true (if the system is operated at a variable pressure at the endings), and so additional
cases may be specified on the control valve data sheet.
The pressure at the control valve inlet is calculated using Equation 1 with:
PUP Pressure of the upstream controlled point (the minimum pressure is to be considered in case
that a range is foreseen, the normal pressure in case of closed loops).
PSH,IN Static head of the inlet line (the minimum liquid level is to be considered for the liquid systems,
except for closed loop, where the normal liquid level is considered, while for the gas systems
the static head is usually negligible).
PPUMP Pump or compressor differential pressure, to be added if a pump or compressor is installed in
the inlet line (minimum liquid density or minimum gas molecular weight to be considered).
PIN Pressure drop of the valve inlet line and equipment at the maximum flow.
The pressure at the control valve outlet is calculated using Equation 4 with:
PDW Pressure of the downstream controlled point (the maximum pressure is to be considered in
case that a range is foreseen and the normal pressure in case of closed loops).
PSH,OUT Static head of the outlet line (the maximum liquid level is to be considered for the liquid
systems when the nozzle is below the liquid level, the nozzle level is to be considered when
the nozzle is above the liquid level, while for the gas systems the static head is usually
negligible).
POUT Pressure drop of the outlet line and equipment at the maximum flow.
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Overdesign margin on the flow rate shall not be specified, unless it is explicitly requested.
Normal opening
The normal operating condition is specified, when the normal operating flow rate is different from maximum
flow rate. Usually, the normal opening case is not specified for normally no flow lines.
PUP Pressure of the upstream controlled point (the normal pressure is to be considered in case
that a range is foreseen).
PSH,IN Static head of the inlet line (the normal liquid level is to be considered for the liquid systems
while for the gas systems the static head is usually negligible).
the inlet line (normal liquid density or normal gas molecular weight to be considered).
PIN Pressure drop of the inlet line and equipment at the normal flow.
PDW Pressure of the downstream controlled point (the normal pressure is to be considered in case
that a range is foreseen).
PSH,OUT Static head of the outlet line (the normal liquid level is to be considered for the liquid systems
when the nozzle is below the liquid level, the nozzle level is to be considered when the nozzle
is above the liquid level, while for the gas systems the static head is usually negligible).
POUT Pressure drop of the outlet line and equipment at the normal flow.
Minimum opening
The minimum opening condition corresponds to the turndown conditions for the circuit. Considering a
constant pressure at both ends of the circuit, at the minimum volumetric flow rate corresponds the minimum
pressure drop upstream and downstream of the valve, and so the maximum pressure drop across the control
valve.
PUP Pressure of the upstream controlled point (the maximum pressure is to be considered in case
that a range is foreseen and the normal pressure in case of closed loops).
+ PSH,IN Static head of the inlet line (the maximum liquid level is to be considered for the liquid
systems, except for closed loop, where the normal liquid level is considered, while for the gas
systems the static head is usually negligible).
the inlet line (maximum liquid density or maximum gas molecular weight to be considered, and
head rise due to the reduced flow rate, if the pump or compressor curve is not available, 20%
of head rise with regard to rated conditions may be preliminarily considered),
- PIN Pressure drop of the inlet line and equipment at the minimum flow.
PDW Pressure of the downstream controlled point (the minimum pressure is to be considered in
case that a range is foreseen and the normal pressure in case of closed loops).
- PSH,OUT Static head of the outlet line (the minimum liquid level is to be considered for the liquid
systems when the nozzle is below the liquid level, the nozzle level is to be considered when
the nozzle is above the liquid level, while for the gas systems the static head is usually
negligible).
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POUT Pressure drop of the outlet line and equipment at the minimum flow.
Minimum pressure drop for control

Apparently, it may look convenient to maintain the valve pressure drop as low as possible, but the ability of
the valve to regulate is ensured only by its capacity to dissipate pressure.
Whenever the pressure drop across the valve decreases with respect to the circuit pressure drop, the valve
ability to control the flow decreases rapidly, as a significant change in valve opening corresponds to an
insignificant change in circuit flow rate.
The following shall be considered:
 The minimum pressure drop of the control valve should be about 20% of the total circuit friction
pressure drop (including the control valve); this may seem excessive, but by removing the valve the
circuit flow rate would be increased by about 12% only. For valves installed on long or high pressure
drop lines, this constraint may be relaxed on a case by case basis.
 For liquid service, the valve pressure drop at maximum operating flow rate should not be lower than 0.5
bar.
Specific cases
6.1.1.1 Discharge to flare

For valves discharging to flare, it is important to decide if the valve is sized to discharge to flare the full plant
flow or only a portion of that.
In the maximum opening case, the upstream pressure is usually the maximum operating pressure, while the
discharge pressure may be the maximum backpressure downstream of the valve or the built up
backpressure due to the control valve discharge. In case the maximum backpressure downstream of the
valve is used for valve sizing, also the case with the normal backpressure downstream of the valve should be
specified, as it may be the sizing case for the noise.
In the minimum opening case, the flow rate should not be more than 10% of the maximum opening case, to
avoid reducing the operating pressure too quickly when only a small discharge is required.
In the minimum opening case, the upstream pressure is again usually the maximum operating pressure,
while the discharge pressure is the superimposed back pressure, often close to atmospheric pressure.
6.1.1.2 Pump minimum flow

The control valves on pump minimum flow line need often to be sized when the information on pump
minimum flow and pump curve is not yet available.
In this scenario, the maximum opening case considers the estimated pump minimum stable flow (refer to
CR-COR-ENG_PRC-002) as preliminary value to be confirmed when pump information is available. The
minimum liquid density is to be considered.
Minimum opening case should be sized as 10% of the pump minimum stable flow, and considering the head
rise due to the reduced flow rate (that may be estimated as 20% of the pump differential head). The
maximum liquid density is to be considered.
6.1.1.3 Self-actuated pressure control valves

Self-actuated pressure control valves (PCV) do not depend on any external signal for pressure control. As
the name suggests, pressure in the process line itself is used as an actuating signal to open or close the
pressure control valve.
A self-actuated pressure control valve can be used to control the pressure at either upstream or downstream
of the control valve. If the upstream pressure is controlled, the valve is known as backpressure control valve.
Self-actuated pressure control valves can be used only with clean fluid services.
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Figure 3 – P&ID sketch of downstream pressure regulating valve and backpressure control valve
A self-actuated pressure control valve uses a feedback tube which allows the process fluid to pressurize the
diaphragm. The process fluid in the feedback tube acts to open the valve, so that process fluid from process
line can pass through. The feedback tube is connected with the upstream section in case of backpressure
control valves, and to downstream section in case of downstream pressure regulating valve.
Figure 4 – Sketch of a downstream pressure regulating valve
In a downstream pressure regulating valve, when the pressure downstream of the control valve increases
beyond the set point, the process fluid increases the pressure on the diaphragm, closing the valve. The
closure of the valve stops the process fluid flow, allowing a reduction of the valve downstream pressure back
to set point. When the pressure downstream of the control valve drops below the set point, then the pressure
on diaphragm is reduced and this causes the valve to open to allow increased flow. The increased process
flow leads to increase the downstream pressure back to its set point.
A downstream pressure regulating valve is intrinsically fail open: in case of a rupture in the feedback tube the
valve reads zero pressure in the downstream section and so opens.
A backpressure control valve is intrinsically fail close: in case of a rupture in the feedback tube the valve
reads zero pressure in the upstream section and so closes.
Self-actuated pressure control valves are used on small diameters (typically at or below 2”).
Self-actuated control valves are specified in the same way as conventional control valves, with maximum,
normal and minimum opening cases. For backpressure control valves the inlet pressure is constant among
the cases, while for downstream pressure regulating valve the outlet pressure is constant among the cases.
Typical applications for PCVs are gas blanketing of storage tanks, machine bearing sealing systems, gas to
furnace pilot.
6.2 FLOW COEFFICIENT PRELIMINARY CALCULATION

The following sizing equations are intended to preliminarily predict the flow coefficient (C V) for compressible
and incompressible fluids through control valves. They are not applicable to slurries, dry solids or non-
Newtonian fluids.
The scope of the flow coefficient preliminary calculation is the evaluation of the process rangeability and the
preliminary evaluation of blow-by scenarios.
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The flow coefficient (CV) is the worldwide recognised parameter to identify the flow rate that can flow through
a valve.
In imperial units, the flow coefficient C V is defined as the amount of water at 60°F (15.56°C) in gallons /
minute that flows through a valve due to a pressure drop of 1 psi. Thus a C V flow coefficient of 7 indicates
that a 1.0 psi pressure drop occurs with a 7 gallons / minute of water throughput through the valve.
In metric units, the flow coefficient K V is defined as the amount of water at a temperature between 5°C (41°F)
and 40°C (104°F) in m3/hour that flows through a valve due to a pressure drop of 1.0 bar.
As the use of the CV is much common than the KV, in this document the CV has been considered.
The following relationship exist between the two parameters.
Equation 5
C V =1.156 ∙ K V
The following equations are applicable for turbulent flow through the valve, which represents the great
majority of the industrial cases.
Gas and Vapours

Based on experimental data, for low valve pressure drop, the flow through a control valve is proportional to
the square root of the pressure drop. Decreasing the outlet pressure, at a certain point there is no further
increase of the flow rate. This is because when the velocity in the vena contracta (refer to section 21) equals
the sound velocity there is no possibility of further increase.
Figure 5 – Flow rate variation based on pressure drop
The non-choked flow regime occurs when the velocity in the vena contracta is less than sound velocity; in
such conditions, the flow rate through the valve depends on the valve outlet pressure.
The choked flow regime occurs when the velocity in the vena contracta is the sound velocity; in such
conditions, the flow rate through the valve doesn’t depend on the outlet pressure.
The valve pressure drop ratio x is defined as the differential pressure divided by the inlet pressure.
Equation 6
P¿−P OUT
x=
P¿
For a given control valve, when the outlet pressure is the maximum pressure causing a choked flow
condition in the vena contracta, the above parameter x is defined as x T. The parameter xT depends on the
valve geometry, and is provided by the valve manufacturer based on experimental tests.
Final values for xT are given by the valve Vendor. For preliminary sizing only, the following typical value may
be used, a more detailed list of values is in IEC 60534-2-1 section D.2.
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Table 1 – Typical values for xT

Valve type xT
Ball 0.3
Butterfly 0.4
Eccentric plug 0.55
Globe 0.7
The choked flow pressure drop ratio is corrected by the factor F  to take into account the gas specific heat
ratio.
Equation 7
x choked =F γ ∙ x T
Where F is calculated using the following equation:
Equation 8
c P /c v
Fγ=
1.40
Hence, the pressure drop ratio to be used for flow rate calculation is limited by the choked flow pressure drop
ratio:
Equation 9
x sizing =min ⁡( x , xchoked )
The gas expansion factor Y takes into account the density change as the fluid passes from the valve inlet to
the vena contracta, and the change in the vena contracta area as the differential pressure is varied.
Equation 10
x sizing
Y =1−
3 ∙ x choked
In choked flow conditions xsizing=xchoked, so Y=0.667
The following equation is used to calculate valve C v.
Equation 11
W (T +273.15) ∙ R ∙ z
C v=
27.3∙ Y ∙ P¿ ∙ F P
∙
√ x sizing ∙ MW
The parameter FP takes into account the effect of pipe reducers. For preliminary calculation consider F P=1;
for detail calculation refer to section 35.2.
Liquids
This section is applicable when a liquid is sent to a control valve. The control valve outlet may be liquid or
mixed phase.
Also for liquids, two different flow regimes may be found in C v calculation: non-choked and choked.
The non-choked flow regime occurs when the valve pressure drop is enough low to avoid significant
formation of vapour bubbles in the vena contracta. This happens when the static pressure in the vena
contracta is higher than the liquid vapour pressure at flowing conditions.
The choked flow regime occurs when the static pressure at the vena contracta significantly decreases
below the fluid vapour pressure. As soon as cavitation is important, the flow rate is independent from the
pressure drop.
There are two different possibilities of choked flow regime:
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Cavitation is the transformation of a portion of liquid into the vapour phase during rapid acceleration of the
fluid on the restriction orifice and the collapse of vapour bubble downstream. The static pressure
downstream the restriction is recovered above the vapour pressure.
Control valve shall be sized to avoid cavitation phenomenon which leads to noise, vibrations, erosion and
possible damages. The correct choice of the valve and the fluid direction may prevent from occurrence of
cavitation.
Flashing: In the case when the downstream static pressure remains below the fluid vapour pressure, then
the vapour bubbles remain in the downstream flow, and the process is referred to as flashing.
Figure 6 – Cavitation and flashing pressure profile
The liquid critical pressure ratio factor F F is the ratio of the vena contracta pressure P VC at choked flow
conditions to the vapour pressure of the liquid P V at inlet temperature.
Equation 12
PVC
FF=
Pv
The value of FF is estimated using the following equation, where P C is the true critical pressure of the fluid.
Equation 13
PV
F F =0.96−0.28 ∙
√ PC
The liquid pressure recovery factor FL is a dimensionless expression of the pressure recovery ratio in a
control valve. It is a function of the valve construction; in general, the more streamlined is the valve, the more
pressure recovery is experienced. Actual value of FL is determined by experimental test.
Equation 14
P¿ −POUT
F L=
√ P¿ −PVC
Final values for FL are given by the valve Vendor. For preliminary sizing only, the following typical value may
be used:
Table 2 – Typical values for FL
Valve type FL
Ball 0.6
Butterfly 0.65
Eccentric plug 0.8
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Globe 0.9
A more detailed list of values is in IEC 60534-2-1 section D.2. Final values are provided by valve
manufacturers.
The above Equation 14 is applicable to non-choked flow.
The choked flow differential pressure is the differential pressure that when exceeded, a further increase in
differential pressure at constant upstream pressure no longer produce a corresponding increase in flow
through the control valve, due to sonic velocity in the vena contracta.
The choked flow pressure drop is calculated with the following equation.
Equation 15
2
∆ Pchoked =F ∙ ( P¿ −F F ∙ PV )
L
Liquid flow is not choked when

Equation 16
∆ P< ∆ P choked
The pressure drop used for control valve CV calculation is limited by the choked flow pressure drop:
Equation 17
∆ P sizing =min ⁡( ∆ P , ∆ Pchoked )
The following equation is used to calculate valve C v.
Equation 18
W 1
C v= ∙
√
27.3∙ F P ∆ P sizing ∙ ρl
The parameter FP takes into account the effect of pipe reducers. For preliminary calculation consider F P=1;
for detail calculation refer to section 35.2.
Two phases
Generally it is better to avoid having control valves with mixed phase at the inlet, because the control
capacity is lower than the one of valves with a single phase at the inlet; however in some cases this choice is
unavoidable or profitable. Moreover in some blow by scenarios, calculation with mixed phase is required.
The following equation is used:
Equation 19
fl f ∙(T + 273.15)∙ R ∙ z
CV=
W
∙
√ + g2 2
27.3 ∙ F P ∆ Psizing ∙ ρl P¿ ∙Y ∙ x sizing ∙ MW
Where Psizing and xsizing are calculated based on Equation 17 or Equation 9 respectively, and Y is calculated
as per Equation 10.
Rangeability
The rangeability is the ratio between the maximum and minimum controllable flows through a control valve. It
is defined as the ratio between C V at max controllable flow and C V at min controllable flow. The minimum
controllable flow is not the leakage flow (which occurs when the valve is closed).
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Equation 20
Cv MAX CONTROLLABLE
Ra=
Cv MIN CONTROLLABLE
This parameter is essential to evaluate if the required service can be satisfied using a single control valve.
The valve rangeability depends on the selected valve.
The process rangeability is the ratio between the calculated valve C V at maximum opening required by the
control valve process specification and the valve C V at minimum opening required by the control valve
process specification.
Equation 21
Cv MAX
RaP =
Cv MIN
As the commercial control valves have standard values of C V, the installed CV is bigger than the one required
for process reasons, due to this, process rangeability is always lower than the valve rangeability advertised
by the Vendors.
Typical process rangeability is:
 For standard globe valves about 20-25.
 For butterfly valves about 15.
 For eccentric rotary plug valves about 30-50.
If the required process rangeability is higher than the above values, then the installation of two parallel
control valves may be required after verification with instrument function: a small valve for the little flow rates
and a bigger valve for the large flow rates.
10.1 ADDITIONAL REQUIREMENTS
Fail position
The fail position of a control valve is the position where the control valve moves in case of loss of instrument
air (or hydraulic oil, electric power) or control signal.
The following choices are available:
 Fail closed, air to open (FC). Typically a spring tends to close the valve, while instrument air is used to
regulate valve position opening the valve as required. In case of loss of instrument air (or control signal)
the spring forces the valve to close.
 Fail open, air to close (FO). Typically a spring tends to open the valve, while instrument air is used to
regulate valve position closing the valve as required. In case of loss of instrument air (or control signal)
the spring forces the valve to open.
 Fail lock (FL). In case of loss of instrument air or control signal, the valve remains in the last position.
 Fail last drift to close (FLC). In case of loss of instrument air or control signal, the valve tends to remain
in the position. In the long term the valve tends to close.
 Fail last drift to open (FLO). In case of loss of instrument air or control signal, the valve tends to remain
in the position. In the long term the valve tends to open.
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Figure 7 – Fail open and fail close actuators
The correct choice of the fail position is important to safeguard the plant. As the fail position is reached in
case of upset, it should be “fail safe”; this means that the fail position should be such that in case of upset the
plant safety is guaranteed.
Typically the following is applicable:
 Fail close valves are frequently used, to shut down the process in case of upset.
 Fail open valves are typically used for pump minimum flow, compressor anti-surge and reflux valves.
 Fail last valves are used in particular cases, such as fuel gas for purge.
Valve fail position shall be defined following a plant general philosophy and considering the consequences
on the whole plant in case of instrument air failure.
Maximum not controlled flow rate

In some cases a control valve has the function to allow a certain maximum flow rate, without the requirement
to control such maximum flow rate; the requirement to effectively control is limited to lower values of flow
rates. In this case the maximum flow rate case is designated as “Maximum not controlled flow rate”. An
example is when a control valve discharging to flare is sized to discharge the full flow (no control
requirement) or only a small relief in case of high pressure (with control requirement).
The designation “maximum not controlled flow rate” allows the valve to be sized to work close to the full
opening condition, where the valve is not expected to effectively control the flow rate. Refer to section 25.
The opportunity to specify maximum not controlled flow rates is useful to avoid the installation of oversized
control valves, more expensive and sometimes cause of problems.
On/off service
In some cases a control valve is used on a circuit that is normally no flow, or where the flow rate is very low.
A typical example is the control valve on the liquid from a normally dry compressor KO drum. In such cases it
is preferable to install an on/off control valve, that is a control valve that is normally fully closed, and when it
is required to operate (high liquid level in the example) opens completely, without the possibility to remain in
an intermediate position. When the condition to open is no more valid, the valve is fully closed.
For control valves in on/off service, only the maximum flow rate is specified.
Mechanical stop
The mechanical stop is a device that mechanically limits the opening of a control valve within a certain limit.
The limitation can be in opening (the valve can’t open more than a certain percentage) or in closing (the
valve can’t close more than a certain percentage).
It may happen that the purchased valve has a C V that is considerably bigger than the required C V at
maximum flow conditions. When the valve is involved in a gas blow-by scenario, this is undesirable. To limit
the discharge flow in case of gas blow-by, it may be helpful to install an internal non-removable mechanical
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stop. In this way the maximum valve opening to be considered in the calculation of the discharge scenario is
limited by the mechanical stop.
On the other hand it may happen that a minimum flow rate is to be ensured on a line to avoid condensation.
In this case a mechanical stop may be installed to avoid the full closure of a control valve.
Maximum differential pressure on closed valve

The maximum differential pressure on closed valve is defined as the maximum differential pressure that can
be developed across the valve. It is required because it defines the design of the actuator. All the operating
scenarios, including start-up and shut-down, shall be considered in the evaluation of the most demanding
case.
The possibility to consider the maximum differential pressure on closed valve as the design pressure of the
upstream / downstream circuit should be limited to the cases where it is really necessary, with the aim to
avoid unnecessary oversizing of the actuators (e.g. when a pressurization bypass is provided or when the
downstream circuit conditions are such that the differential pressure is always lower than shutoff).
Solenoid valve
When a control valve needs to be closed / open in an emergency scenario, a solenoid valve is provided on
the instrument air to the control valve. Typically the solenoid valve is managed by Safety Integrated System
(SIS) or Distributed Control System (DCS) according to the Safety Integrity Level (SIL) requirement, and
when activated forces the control valve to its fail, independently from the control demands.
The use of control valves for emergency shut-down function is often not allowed by the Client design
requirements.
Valve stroke time

The valve stroke time is defined as the travel time from full open to full close position (or vice versa). Usually
it is not required but in some special cases it is necessary to specify (as a note on the data sheet) a
maximum or a minimum valve stroke time.
Some examples are:
 the compressor anti-surge valve, where a maximum travel time requirement is often specified in order to
provide fast opening of the valve (typical values 1-2 seconds from fully close to fully open condition).
 valves on a liquid lines that may need to be slowly closed to avoid water hammer.
Leakage classes
The control valve leakage classes are defined by ANSI/FCI 70−2 and IEC 60534-4. Six classes are defined,
from class I (maximum leakage) to class VI (minimum leakage).
The most used classes are III, IV and V.
 Class III can be used for liquid service.
 Class IV is typically used for control valve discharging into the process, where a leakage does not imply
a product loss.
 Class V is typically used for control valve discharging to flare, to avoid product loss in case of leakage.
For leakage class details refer to section 35.1.
Limit switch
Limit switches are accessories that can be added to a control or block valve to have indication or initiate logic
actions when the valve reaches the fully open or closed position.
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Figure 8 – Limit switch P&ID representation

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20 ATTACHMENTS
20.1 THEORY
Flow path and Vena Contracta

The flow path through a control valve is complex, including regions of high turbulence.
Figure 9 – Flow path through a globe type control valve
As the flow passes from the valve inlet to the trim inlet, the static pressure reduces due to frictional and
turning losses. The following figure sketches the fluid streamlines inside a control valve.
Figure 10 – Contraction of stream lines
Due to the contraction in the valve trim, the static pressure decreases (see Figure 11) and the fluid velocity
increases. Subsequently to the passage through the minimum geometrical flow area, the streamlines
continue to contract until at a point (just downstream from the trim outlet) where the streamlines becomes
parallel. This minimum flow area is referred to as the vena contracta. At this point, the minimum static
pressure and maximum flow velocity occur. The pressure at the vena contracta, in relation with the upstream
pressure and the fluid vapour pressure, is important to determine the flow rate through the valve.
Downstream of the vena contracta, the flow area expands resulting in a flow velocity reduction and a static
pressure increase. The amount of pressure recovery is a function of the valve trim technology.
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Figure 11 – Variation in static pressure and velocity
Inherent flow characteristics

The inherent flow characteristic of the control valve is the relationship between the valve capacity and the
valve stem travel. The valve trim design affects how the control valve capacity changes as the stem moves
through its complete travel. Because of the variations in trim design, many valves are not linear in nature.
The valve trims are instead designed, or characterized, in order to meet the large variety of control
application needs.
In order to graphically show the inherent flow characteristic of a control valve, the percentage of flow through
the valve is plotted against the valve stem position. These curves are based on constant pressure drop
across the valve. Refer to the following Figure 12.
Independently from the size and the inherent flow characteristic, valves with the same C V, fully open and
subject to the same differential pressure, allow the same volumetric flow rate.
However, different valve characteristics cause different percentages of stem travel for the same pass area.
Comparing linear and equal percentage valves, a linear valve might have a 25% stem travel for a certain
pressure drop and flow rate, whilst an equal percentage valve might have a 65% stem travel for the same
conditions. The orifice pass areas is the same.
The following typical inherent flow characteristics are available:
 Linear: flow is directly proportional to the valve lift.
Equation 22
C V ∂=%opening ∙ CV
 Equal Percentage: equal increments of valve lift produce an equal percentage in flow change.
Equation 23
C V ∂=C V ∙ Ra(% opening −1)
 Quick opening: large increase in flow with a small change in valve lift. Unlike linear and equal
percentage characteristics, the exact shape of the fast opening curve is not defined in standards.
The majority of control valves used in industrial plants are with linear or equal-percentage inherent flow
characteristic, however several other types of characteristics are available.
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Figure 12 – Typical inherent flow characteristics of control valves
100%
90%
80%
70%
% of maximum flow
60%
50% Linear
40% Equal percentage
Quick opening
30%
20%
10%
0%
0%
%
%
%
%
%
%
%
%
%
%
%
8%
24
32
56
64
88
96
16
40
48
72
80
% of stem travel
A valve with linear inherent flow characteristic is typically used:

 When more than 40% of the circuit P is across the valve.
 When high rangeability is not required.
 When both inlet and outlet pressures are stable.
 When major disturbance in the process are load changes.
A valve with equal percentage inherent flow characteristic is typically used:
 When good control is required at small openings.
 When high rangeability is required.
 When less than 40% of the circuit P is across the valve.
A valve with quick opening inherent flow characteristic is used:
 For on/off control valves.
Installed flow characteristics

The installed Flow Characteristics is the relationship between the system mass flow rate and the stem
travel. It depends on the valve inherent characteristic and on the system pressure drop.
The following figures show the variation of the installed flow characteristics based on the ratio between the
valve pressure drop and the total circuit pressure drop (including the valve). The 100% case considers only
the valve pressure drop, and so it coincides with the inherent flow characteristic of the valve.
The installed flow characteristic of a properly designed circuit should be not far from the linear.
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Figure 13 – Installed flow characteristics for a linear control valve

100%
90%
80%
70% Valve P /
% of System flow rate
60% System P
50%
40% 15%
30% 25%
50%
20%
100%
10%
0%
0% 1 0 % 2 0 % 3 0 % 4 0 % 50 % 60 % 70 % 80 % 90 % 0 0 %
1
% of stem travel
Figure 14 – Installed flow characteristics for an equal percentage control valve
100%
90%
80% Valve P /
% of system flow rate
70% System P
60%
50% 15%
40% 25%
50%
30%
100%
20%
10%
0%
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1
% of stem travel
Gain
The control valve gain is the ratio of the percentage change in the flow rate to the percentage change of the
valve travel. It is the derivative of the valve inherent flow characteristic.
The gain of a control valve is defined as follows:
Equation 24
∆ % (Flow Rate)
Gain=
∆ %( Stroke∨Travel)
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Available stem travel

As it can be seen in the above pictures, in the zones close to 0% and close to 100% of the stem travel, the
circuit flow rates varies a lot (linear valve close to 0%, equal percentage valve close to 100%) or a few (linear
valve, close to 100%, equal percentage valve, close to 0%).
In these zones the system controllability is not optimal. Due to this, the stem travel calculated for maximum
flow case and minimum flow case is usually limited to the range 10÷90% (these values vary depending on
the valve type and on client requirements). Only in case a maximum not controlled flow rate is specified, this
can be close to 100% of the stem travel.
Direct and reverse actuators

A direct actuator is an actuator in which the actuator stem extends increasing the diaphragm pressure. A reverse
actuator is an actuator in which the actuator stem retracts increasing diaphragm pressure.
A direct acting valve is a valve that travels to the closed position when the signal increases. A reverse acting
valve is a valve that travels to the open position when the signal increases.
Figure 15 – Sketch of direct and reverse actuator and valve action
Multi-stage control valves

One method to avoid the cavitation is to use a multi stage control valve.
In a multi stage control valve the total valve pressure drop is split in a series of smaller pressure drop, such
that the recovered pressure in each pressure drop is much smaller than the recovered pressure in a
conventional valve.
The Pressure Recovery factor for a multi stage control valve is close to 1.
Figure 16 – Sketch of a multi-stage control valve
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Figure 17 – Pressure profile in a three stages control valve
27.1 VALVE TYPES

Due to the variety of systems, fluids and environment where the valves operate, a wide variety of valve types
have been developed. Each type of valve is designed to meet specific needs.
The following two categories can be defined:
1. Sliding valves (the valve closure member has a linear movement)
a. Globe valve
i. Single seated
ii. Cage type
iii. Angle valve
iv. 3-way
b. Needle valve
c. Diaphragm valve
d. Gate valve (not used as control valve)
e. Axial valve
2. Rotating valves (the valve closure member has a rotational movement)
a. Butterfly valve
b. Ball valve
c. Plug valve
Globe valve
The most common control valve style is the globe valve, which is a stroke type control valve.
The principle of globe valve operation is the linear movement of the plug towards or away from the seat. This
causes the annular space between the disk and seat ring to gradually close as the valve is closed. This
characteristic gives to the globe valve good throttling ability, which allows the use for flow regulation.
The main drawback of the simple globe valve is the high head loss due to two or more right angle turns of
flowing fluid. In a large high-pressure line, the fluid dynamic effects can damage the trim, the stem packing,
and the actuator. In addition, large valve sizes require considerable power to be operated.
Globe valves are available for size up to 16”.
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Single seat
Figure 18 – Globe valve with single seat
The single seat is the most common valve body style and is simple in construction. The fluid flow pushes
against the valve plug and tends to keep the plug off the valve seat. Generally single seat valves are
specified for applications with stringent shut off requirements. They use metal-to-metal seating surfaces or
soft-seating.
Cage type internal
Figure 19 – Globe valve with cage type internals
The cage openings are opened and closed by the vertical movement of the valve plug.
Globe valves with cage internal are suitable for high differential pressure, and are typically used as
compressor anti-surge valve; they are not suitable for dirty fluids.
Angle globe valve
Figure 20 – Angle globe valve
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An angle valve is a globe valve in which one port is co-linear with the valve stem and the other port is at right
angle with the valve stem. It is particularly indicated in case of high differential pressure and in presence of
flashing or viscous fluids. As it has a single seated body, this valve has the advantage of a tight shut-off.
It is typically used as choke valve at the wellheads.
3 ways
3-ways valves are provided with two inlet or outlet. Three way valves are used for blending (two inlet and one
outlet) or as a diverter (one inlet and two outlets)
Needle valve
Figure 21 –Needle valve
The needle valve is used on very small flow rates.

A needle valve is a type of valve having a small port and a threaded, needle-shaped plunger. It allows
precise regulation of flow. A needle valve has a relatively small orifice with a long, tapered seat, and a
needle-shaped plunger, on the end of a screw, which exactly fits this seat.
Diaphragm valve
Figure 22 –Diaphragm valve
Diaphragm valve has very special application in industry, specially where the contamination of the fluid is not
allowed or in case of very hazardous fluid. They are used extensively in the mining industry for control of
slurries and water. These valves are inexpensive and very simple in operation.
The characteristic is basically quick opening and so these valves do not give precise control or high
turndown but function particularly well on level control. Very good for low pressure abrasive applications.
Sizes are available from 1” to 14” in pressure ratings up to 10 barg on the smaller sizes and 3.5 bar above
8”. Special pinch valves can handle pressures up to 100 bar.
Temperature limitation is about 100 °C.
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Butterfly valve
Figure 23 – Butterfly valve
The butterfly valve is a rotary motion valve used to start, stop and regulate fluid flow. The butterfly valve is
easily and quickly operated because a 90° rotation of the handle moves the disk from a fully closed to fully
opened position. Large butterfly valves are actuated by hand-wheels connected to the stem through gears.
The flow control element is a disk of approximately the same diameter as the inside diameter of the adjoining
pipe, which rotates on either a vertical or horizontal axis. When the disk is parallel to the piping run, the valve
is fully open. When the disk approaches the perpendicular position, the valve is shut. Intermediate positions
are used for throttling purposes.
Butterfly valves are suitable to handle large flows of fluid with relatively low pressure drop, and to handle
slurries or liquids with large amounts of suspended solids. The butterfly valve has many advantages
especially for large valve applications: reduced weight, cost and space occupation.
A high performance butterfly valve has a disc that is offset from the shaft centre line; this eccentricity causes
the seating surface to move away from the seal once the disc is out of the closed position. Its advantage is
the improved shutoff while maintaining high capacity and reasonable cost. The cost advantage is particularly
true for nominal diameters above 6”.
Eccentric rotary plug valve

Figure 24 –Eccentric rotary plug valve
Figure 25 –Eccentric rotary plug valve sketch
The plug valve is a rotational motion valve. The name is derived from the shape of the closure member,
which resembles a plug. The body of a plug valve is machined to receive the tapered or cylindrical plug. The
closure member is a solid plug with a passage at a right angle to the longitudinal axis of the plug. In the open
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position, the passage in the plug lines up with the inlet and outlet ports of the valve body. When the plug is
turned 90° from the open position, the solid part of the plug blocks the ports and stops fluid flow.
It is often used in a temperature range from 200 to 400°C.
Ball valve
Figure 26 –Ball valve
The ball valve is a valve with a rotary closure member and a spherical ball located between two sealing rings
in a simple body form. Normally it is used to ensure block function, but if the flow-controlling member uses a
partial sphere with a flow passage through it, it can be used as control valve.
Axial valve
Figure 27 –Axial valve
The axial valve has a streamlined flow path that avoids turbulence and prevents erosion and vibration. The
inherent capacity of the axial valve is very high compared to conventional globe control valves. High inherent
capacity and accurate control features make the valve suitable for applications that require very high
turndown.
It is used for particular applications due to the high cost.
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Summary table
Table 3 – Typical control valve characteristics
Advantages Disadvantages Typical use
Minimum body erosion
Angle Used for high P Complicated piping layout Choke valve
Low noise (with special trim)
High capacity Large rangeability
Axial High turndown
High cost
applications
High capacity
Large rangeability
Ball Low P Heavy for large sizes
applications
Good rangeability
High flow rate and low P Low P applications
Butterfly Light weight Low rangeability Compressor suction
Compact design throttling
Limited operating pressure
Process fluid is isolated from
and temperature Chemical and abrasive
Diaphragm valve stem
Poor control above 50% service
Self-cleaning
opening
Eccentric rotary Good rangeability Large rangeability
Maximum diameter 12"
Plug Good sealing applications
Poor sealing
Cage type Suitable for high P High P
Expensive for large sizes
High pressure losses
For any throttling application
Globe single seat Good sealing
Limited to small size General use
High actuator forces
Needle For low flow rates
35.1 LEAKAGE CLASSES

The seat leakage for control valves is defined as the quantity of test fluid passing through an assembled
control valve in closed position under the defined test conditions.
The control valve leakage classes are defined by ANSI/FCI 70−2 and IEC 60534-4.
The definition TSO (tight shut off) is improperly used when applied to control valves, as it refers to shut-off
valves.
Class I
Class I leakage simply states as agreed upon between purchaser and manufacturer. It does not identify a
test procedure or specify a standard test pressure and, therefore, does not define the maximum allowable
leakage.
Classes II–IV
The maximum allowable leakage for each class is expressed as a function of the rated valve capacity as
follows, based on a test pressure of 3-4 bar or maximum operating differential pressure, whichever is lower,
with clean air or water at 10-51°C.
 Class II: 0.5% of rated valve capacity
 Class III: 0.1% of rated valve capacity
 Class IV: 0.01% of rated valve capacity.
Class V
Class V represents what is commonly referred to as an “effectively zero-leakage” control valve.
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The maximum allowable leakage is 5*10 -12 m3/s of water per mm of seat diameter per bar differential; or
11.1*10-6 Sm3/h of air per mm of orifice diameter. Test pressure is maximum service pressure drop across
valve plug.
Class VI
The maximum allowable leakage is as per the following table. Test pressure is 3.5 bar (50 psig) or maximum
rated differential pressure across valve plug, whichever is lower.
Table 4 – Class VI allowable leakage factors
NOMINAL PORT
LEAKAGE
DIAMETER
in ml per minute Bubbles per minute
1” 0.15 1
1.5” 0.30 2
2” 0.45 3
2.5” 0.6 4
3 0.9 6
4 1.7 11
6 4 27
8 6.75 45
10 11.1 N/A
12 16 N/A
14 21.6 N/A
16 28.4 N/A
35.2 EFFECT OF PIPE REDUCERS
Calculation of FP
When valves are mounted between pipe reducers, there is a decrease in the actual control valve capacity.
The reducers cause an additional pressure drop in the system, in series with the valve. The piping geometry
factor FP is used to account for this effect, to be used for a detailed CV calculation using Equation 11,
Equation 18 or Equation 19.
Loss coefficients are calculated.
Equation 25
2 2
dV
K 1=0.5∙ 1−
[ ( )]
d¿
Equation 26
2 2
d
[ ( )]
K 2=0.5∙ 1− V
d OUT
Bernoulli coefficients are calculated.
Equation 27
4
dV
K B 1=1− ( )
d¿
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Equation 28
4
dV
K B 2=1− ( )
d OUT
The FP factor is calculated.
Equation 29
C2V ∙( K 1 + K 2 + K B 1−K B 2)
−0.5
F P= ( 0.00214 ∙ d 4
+1 )
When inlet and outlet reducers are the same size, the Bernoulli coefficients cancel out.
Calculation of xTP
xT is the liquid recovery factor for a valve without attached fittings. When the effect of pipe reducers is taken
into account, xT is substituted by xTP in Equation 7.
Equation 30
xT
F 2P
x TP =
2
xT C
√ 1+
0.00241 ( )
∙ ( K 1+ K B 1 ) ∙ V
dV
Calculation of FLP
FL is the liquid recovery factor for a valve without attached fittings. When the effect of pipe reducers is taken
into account, FL should be substituted by FLP in Equation 15.
Equation 31
FL
F LP =
F 2L 2
C
√ 1+
0.00214 ( )
∙ ( K 1+ K B 1 ) ∙ V2
dV
38.1 CONTROL VALVE DATA SHEET

Clarification regarding fields to be filled is shown here below:
Item
Insert the tag of the control valve.
Service
The service is a short description of the controlled stream (e.g. gasoil from separator to storage).
Process requirement on valve type
This is normally omitted to allow the Vendor to select the best solution for the service. Licensed process may
indicate preferred or mandatory valve types.
On power failure
Indicate the position that the valve assumes in case of lack of “feeding” (instrument air, hydraulic oil, electric
power, etc.): Failure open or failure close. It is to be filled also when the valve remains as it is in case of lack
of feeding, to indicate the final position.
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Failure position is selected based on safety considerations.

Process variable to control
The controlled variable is indicated: pressure, temperature, level, flow rate or analyser. Information relevant
to complex controls, if any, are described in the control narrative.
Split range
Indicate yes if the valve works in split range. Otherwise No.
Lock-up
YES is to be indicated when it is required that the valve remains locked in the last position in case of lack of
feeding (valve FLO or FLC). Otherwise NO. Possible lock up is selected based on safety considerations.
In case lock-up is specified, the valve remains in its last position for a specified time, after this time the valve
reaches its safe position, as per failure position requirements.
Leakage class
The leakage class is to be specified. (I to VI)
Jacket
Indicate Yes if the valve has to be kept hot or cold through a jacket. The utility fluid to be used shall be
indicated with a note.
Run description
It is a short description of the cases selected to size the valve.
Fluid description
It is a short description of the fluid: HC liquid, steam, water, naphtha, etc.
Special services
Characteristics of the fluid that determine the material selection of trim and body: Suspended solids (to be
specified), special fluids (H2, O2, Urea, Amine), lethal service, toxic service, sour service, aromatics. The
concentration of the involved compound shall be added in a note.
Flow, inlet and outlet pressure
The operating cases corresponding to:
 maximum volumetric flow rate and minimum pressure drop
 normal volumetric flow rate and normal pressure drop
 minimum volumetric flow rate and maximum pressure drop
are specified.
In some applications it is not necessary to specify all the three cases.
Peak flow
Peak flow can assume two meanings that have to be clearly defined, by means of a dedicated note:
 Maximum flow not to be exceeded at control valve wide open (e.g. to limit blow-by flow rate for PSV
design). In this case an internal mechanical stop may be required.
 Maximum flow rate that has to be guaranteed at control valve wide open (maximum not controlled flow
rate).
Fluid properties at operating conditions
The fluid properties upstream and downstream of the control valve are indicated.
System pressure drop without valve
CORPORATE CRITERIA
Rev. 01 Date 13/12/13
Page 36 of 36
It is the sum of the system pressure drops upstream and downstream of the control valve at maximum flow
condition (therefore with the minimum pressure drop across the control valve). This parameter is useful to
check the controllability of the system, and to select the valve inherent characteristic.
Maximum differential pressure on closed valve
It is the maximum differential pressure at which the valve operation is ensured. This parameter is required to
define the design of the actuator.
Nominal pipe diameter
Inlet and outlet pipe size have to be indicated. Data refer to upstream and downstream lines without
considering relevant reductions.
Typical notes
In case a valve is installed downstream of a pump and operating pressure are estimated: Inlet pressure will
be confirmed after pump (indicate the pump tag) selection.
In case a valve is installed to control pump minimum flow: valve is normally closed and shall be designed in
order to guarantee the highest controllability in the range 0 – 30%. Maximum flow will be confirmed after
pump (indicate the pump tag) selection.
Specific service shall be explained. E.g. in case of toxic service: H2S maximum content 5000 ppm wt.
In case a peak flow is indicated and the figure must not be exceeded for process reasons (e.g. because may
affect the flare design), the following note may be added: Maximum flow rate that cannot be overcome. In
case the selected valve has a CV higher than what required, the valve will be provided with an internal
mechanical stop in order to limit the flow at the indicated value.
The discontinuous service should be indicated in note in order to allow a better approach on the associated
noise limits: Intermittent in case of valve operating in cycle service on a daily basis, Infrequent for those valve
that are not supposed to normally operate (for example, valves that under upset conditions are discharging
to flare or blowdown). For on-off valves, designer to indicate if they have to be considered continuous or
intermittent or infrequent.
If additional accessories are required to be provided with the valve (e.g. limit switches, hand-wheel): Hand-
wheel to be provided.
39.1 TYPICAL PRESSURE DROP FOR FLOW INSTRUMENTS

As a guideline, the typical pressure drops to be considered for flow instruments (at rated flow) are the
following:
Table 5 – Typical pressure drop for flow instruments
Typical pressure drop (bar)
Coriolis 0.5 - 1
Orifice plate 0.25
Ultrasonic 0
Venturi tube 0.05
Vortex 0.5

Control Valve Process Sizing: Corporate Criteria

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CONTROL VALVE PROCESS SIZING

13/12/13 01 First issue S. Ingrosso G. Poni A. Cipelli

Date Revision Description of Revision Prepared Checked Approved

This document is the property of Saipem S.p.A. All rights reserved

13/12/13 01 First issue S. Ingrosso G. Poni A. Cipelli

Date Revision Description of Revision Prepared Checked Approved

1 SCOPE AND PURPOSE 5

5.4 EFFECT OF PIPE REDUCERS 32

1 SCOPE AND PURPOSE

2.2 RECOMMENDED PRACTICES AND CRITERIA

2.3 SAIPEM REFERENCES

Leakage class Classifications established by ANSI/FCI 70-2 to categorize seat leakage

xTP Pressure differential ratio factor at choked Dimensionless

Symbol Definition Unit of measure

The process activities relevant to control valve include:

 Flow coefficient (CV) preliminary calculation (optional).

4.1 DEFINITION OF THE CIRCUIT

Inlet pipe length; D P=XXX Outlet pipe length DP=YYY

4.2 DESIGN AND OPERATING CASES SPECIFICATION

Minimum pressure drop for control

6.1.1.1 Discharge to flare

6.1.1.2 Pump minimum flow

6.1.1.3 Self-actuated pressure control valves

6.2 FLOW COEFFICIENT PRELIMINARY CALCULATION

Gas and Vapours

Table 1 – Typical values for xT

Liquid flow is not choked when

10.1 ADDITIONAL REQUIREMENTS

Figure 7 – Fail open and fail close actuators

Maximum not controlled flow rate

Maximum differential pressure on closed valve

Valve stroke time

Figure 8 – Limit switch P&ID representation

Flow path and Vena Contracta

Figure 11 – Variation in static pressure and velocity

Inherent flow characteristics

C V ∂=C V ∙ Ra(% opening −1)

Figure 12 – Typical inherent flow characteristics of control valves

A valve with linear inherent flow characteristic is typically used:

Installed flow characteristics

Figure 13 – Installed flow characteristics for a linear control valve

Figure 14 – Installed flow characteristics for an equal percentage control valve

Available stem travel

Direct and reverse actuators

Figure 15 – Sketch of direct and reverse actuator and valve action

Multi-stage control valves

Figure 17 – Pressure profile in a three stages control valve

27.1 VALVE TYPES

The needle valve is used on very small flow rates.

Eccentric rotary plug valve

Figure 25 –Eccentric rotary plug valve sketch

35.1 LEAKAGE CLASSES

35.2 EFFECT OF PIPE REDUCERS

38.1 CONTROL VALVE DATA SHEET

Failure position is selected based on safety considerations.

39.1 TYPICAL PRESSURE DROP FOR FLOW INSTRUMENTS

Orifice plate 0.25

Venturi tube 0.05

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