Control Valve Cv Calculation

Hadi Veyse – Oil and Gas Operation Superintendent

Control Valve Cv Calculation

The Cv value shall be calculated in accordance

with:

• IEC 60534-2-1 Industrial-process control valves

- Part 2-1: Flow capacity – Sizing equations for
fluid flow under installed conditions.

OR

• ISA 75.01.01 Industrial-Process Control Valves -

Part 2-1: Flow capacity – Sizing equations for
fluid flow under installed conditions.

The equations in the international edition are

essentially equivalent to the U.S. standard.
Control Valve Cv Calculation

API RP 553 2012:

Control valve sizing should comply with the following criteria:

• Control valve size should be selected so that at the maximum specified flow rate and
corresponding pressure drop, the required travel should not be more than 90% of full travel. In
some cases travel up to 95% may be desired, but this should be avoided, unless the process
conditions present no alternatives.

• Control valve size should be selected so that at the minimum specified flow rate and
corresponding pressure drop, the required travel should not be less than 10% to 20% of full
travel. Proposals to use control valves at lower travel should be reviewed and approved by
Owner's engineer and the valve manufacturer.

• Conventional butterfly valves should be sized for maximum angle opening of 60 degrees.
Proposals to use angles greater than 60 degrees should be reviewed and approved by Owner's
engineer and the valve manufacturer.
Control Valve Cv Calculation

Shell DEP 32.36.01.17 2017:

The calculation of the Cv value should be based on the maximum flow with its related process data.

Unless otherwise specified in the requisition, the following rules shall apply:
a. Qo = 110% x Qmax
b. Qn < 80% x Qmax
c. Qn > 40% x Qmax
d. Qmin > 10% x Qmax

Qmin = Minimum specified flowrate.

Qn = Normal specified flowrate.
Qmax = Maximum specified flowrate.
Qo = Flowrate with fully open valve without taking adjustable travel stops into account.
Qs = Flowrate without control valve.

If the control valve is equipped with a bypass manifold, where the size of the upstream/downstream
piping is DN 50 (NPS 2) or smaller, then Qo shall be 120% of Qmax.

To avoid excessive loop gain variations (> 4), the control valve authority parameter at normal flow
rate shall not be less than 0.27, which results in a Qs of 117% of Qn or more.

A control valve shall be selected with a rated Cv value that is between 110% and 150% of the
highest of the calculated Cv values for the different conditions.

For three-way globe valves, each flow path shall be sized separately.
Control Valve Cv Calculation

Total GS EP INS 120 2018:

For each control valve, the data sheet shall define, as a minimum, the process data for the following
three flow conditions: normal flow rate, maximum flow rate and minimum flow rate.

Control valves should be sized to have an operating stroke between:

• Minimum 10% opening at minimum flow conditions
• 50% to 75% opening at normal flow conditions
• 85% to 90% opening at maximum flow conditions

The process design should allow the normal flow condition between 50% and 75% of the maximum
flow condition, in order to avoid a too limited control valve opening during normal flow conditions.

The selected Cv shall be at least 1.1 times the calculated Cv at the worst case conditions (maximum
flow and lowest available pressure drop).
Control Valve Cv Calculation

Worley KS-PR-DEG-0120 2019:

Usually, process data is specified for operating conditions at minimum flow rate and at normal
and/or maximum flow rate. The control valve is, however purchased based on full open Cv value
(The ‘open’ valve flow rate is a calculated value based upon the normal operating flow or the
maximum operating flow (whichever is applicable) and the flow margin to ‘open’ valve. Usually, the
actual open valve flow will be higher than the calculated ‘open’ valve flow because the selected
control valve Cv value is normally higher than the calculated Cv value).

1) The control valve full open Cv calculation and the selection of valve characteristics depend on
the operating conditions for which the process data has been specified. The following process
data needs to be specified for different flow conditions:

• Inlet pressure (barg)

• Pressure drop (bar)
• System dynamic pressure drop (bar)
• Pump dynamic pressure drop (bar)
• Physical properties of the process fluid

2) Minimum control valve flow conditions – check control valve rangeability:

For the minimum flow rate through the control valve the valve authority is not relevant to calculate.
The minimum control valve flow is required to check:
• The rangeability of the control valve: can the control valve handle the highest and minimum
required Cv values for respectively the minimum and normal flow (or maximum when required).
• To check the controllability at minimum flow; however, this is usually not applied.
Control Valve Cv Calculation

Worley KS-PR-DEG-0120 2019:

3) Cv value calculation at normal flow conditions:

This calculation requires the process data to be specified at the minimum flow rate and normal flow
rate. The step-by-step procedure is as follows:
i. Calculate the Cv value at normal operating flow.
ii. Calculate control valve authority at normal operating flow.
iii. Read the (Cvn/Cvo) factor from below table corresponding to the calculated control valve
authority:

iv. Calculate the full open Cv value.

v. Read the control valve characteristics from above table corresponding to the calculated control
valve authority.
vi. Select the control valve based on the characteristics and calculated full open Cv value.
vii. Calculate the Cv value at minimum flow and check if the selected control valve can handle it.
Control Valve Cv Calculation

Worley KS-PR-DEG-0120 2019:

4) Cv value calculation at maximum flow conditions:

This calculation requires the process data to be specified at the minimum flow rate and maximum
flow rate. The step-by-step procedure is as follows:
i. Calculate the Cv value at maximum operating flow.
ii. Calculate control valve authority at maximum operating flow.
iii. Read the (Cvmax/Cvo) factor from below table corresponding to the calculated control valve
authority:

iv. Calculate the full open Cv value.

v. Read the control valve characteristics from above table corresponding to the calculated control
valve authority.
vi. Select the control valve based on the characteristics and calculated full open Cv value.
vii. Calculate the Cv value at minimum flow and check if the selected control valve can handle it
Control Valve Cv Calculation

Worley KS-PR-DEG-0120 2019:

5) Cv value calculation at normal and maximum flow conditions:

This calculation requires the process data to be specified at the minimum flow rate, normal flow
rate, and maximum flow rate. The step-by-step procedure is as follows:
i. Follow the step-by-step procedure as mentioned in Cv value calculation at normal flow
conditions.
ii. Follow the step-by-step procedure as mentioned in Cv value calculation at maximum flow
conditions.
iii. Select the control valve based on the highest calculated full open Cv value and the
corresponding valve characteristics.
Control Valve Cv Calculation

Saudi Aramco PCI10302:

While it is sometimes tempting to select and size control valves for the maximum flow condition
only, it is equally important to calculate Cv requirements at normal and minimum flow conditions:

• Sizing for maximum flow ensures adequate capacity.

• Sizing for normal flow conditions allows the specifier to ensure that the valve will normally
throttle in a range of travel (or percentage of maximum valve Cv) that provides good control and
sufficient reserve capacity.
• Sizing for minimum flow conditions allows the specifier to ensure that the valve is capable of
providing stable control at the low-flow condition. Most valves are designed to provide good
control down to about 10 percent of rated travel. Throttling below 10 percent travel can cause
system instability because of the high valve gain at low lifts, and it can cause high velocity flow
that results in accelerated seat wear.

Most valve manufacturers use a rule of thumb that establishes acceptable percentages of travel for
the minimum, normal, and maximum flow conditions:
Control Valve Cv Calculation

Saudi Aramco SAES-J-700 2018:

The selected control valve trim capacity (Cv selected) shall meet the following:

• An equal percentage trim shall operate below 93% travel at maximum flow condition. If no
maximum flow condition is specified on the ISS (Instrument Specification Sheet), then the trim
shall operate below 85% travel at normal flow condition.
• A linear trim and quick opening trim shall operate below 90% travel at maximum flow condition.
If no maximum flow condition is specified on the ISS, then the trim shall operate below 75%
travel at normal flow condition. Anti-surge control valves shall operate below 55% travel at
maximum flow condition.
• A modified parabolic trim shall operate below 90% travel at maximum flow condition. If no
maximum flow condition is specified on the ISS, then the trim shall operate below 80% travel at
normal flow condition.

Commentary Note:
The specified percentage (%) travel positions are for sliding stem type valves and need to be
converted to degrees opening for rotary type control valves.

Saudi Aramco PCI10302: The guidelines for travel versus flow are expressed in percent travel and
apply directly to sliding-stem valves; however, travel for rotary-shaft valves is expressed in degrees
rotation. In order to apply the recommended percentages listed above to rotary-shaft control valves,
percentages of travel must be converted to degrees rotation; for example, if the maximum
acceptable travel for a given condition is 93 percent, the equivalent rotation is approximately 84
degrees (0.93% x 90 degrees = 84 degrees).
Control Valve Cv Calculation

Chevron ICM-SU-5102-C.3 2018:

Rangeability (Ratio of the largest flow coefficient, Cv, to the smallest controllable Cv, within which
the deviation from the specified flow characteristic does not exceed the stated limits. Essentially, this
is the ratio of the maximum controllable flow to the minimum controllable flow as defined in this
specification):

1) High rangeability shall be defined as follows:

a. Design minimum condition occurs at less than 15 percent or 20 degrees of valve travel.
b. Design maximum condition occurs at greater than 80 percent or 75 degrees of valve travel.

2) If high rangeability is required, two control valves in parallel shall be used. Exceptions to this
requirement shall be submitted to Purchaser for review and agreement.
a. The smaller valve shall be sized using the minimum condition at approximately 60 percent or
approximately 55 degrees of stem travel.
b. The larger valve shall be sized to meet the other sizing conditions (such as normal and
maximum conditions).

Note: If it is determined that two control valves in parallel are required, the designer should confer
with the process engineer and process control system (PCS) engineer for configuration and tuning.
Control Valve Cv Calculation

Chevron ICM-SU-5102-C.3 2018:

Operating Range (Ratio of the maximum usable flow to the minimum usable flow):

1) Operating ranges for linear motion valves shall comply with the following:
a. The operating Cv through all conditions shall be sized to operate within 15 percent through 80
percent of stem travel.
b. Operating Cv at normal condition shall be within 40 percent through 65 percent of stem travel.

2) Operating ranges for rotary valves (except butterfly valves) shall comply with the following:
a. Operating Cv through all sizing conditions shall be sized to operate within 15 to 75 degrees of
stem rotation.
b. Normal condition Cv shall be sized to operate within 30 to 60 degrees of stem rotation.

3. Butterfly valves shall have an operating range of 20 through 40 degrees of disc rotation. If the
butterfly valve is a “high performance” type, operating range shall be 20 through 50 degrees of
disc rotation.
Control Valve Cv Calculation

PIP PCCCV001 2016:

Operating Range:

1) Operating ranges for linear motion valve types shall be in accordance with the following:
a. In cases where high rangeability (design minimum flow occurs at less than 20% of valve travel),
or high capacity is required, two control valves in parallel shall be used, and owner’s approval
shall be required.
b. If high rangeability is required, the smaller valve shall be sized using the minimum process
design flow as the maximum flowrate of the valve. The larger valve shall be sized in accordance
with this Specification. Owner’s approval shall be required.
c. For most operating conditions, the Cv of a control valve shall be sized to operate within 15%
through 80% of maximum rated Cv for the control valve.
d. For normal design flow conditions, valve travel shall be within 40% through 70%.

2) Operating range for rotary valves (except butterfly valves) shall comply with the following:
a. Operating Cv through all sizing conditions shall be sized to operate within 15° to 75° of control
valve stem rotation.
b. Normal flow Cv shall be sized to operate within 30 degrees to 60 degrees of control valve stem
rotation.

3) Butterfly and eccentric disc valves shall have a minimum through maximum operating range of
20° through 60°of disc rotation. If the butterfly valve is a “high performance” type, then the
minimum through maximum operating range shall be 15° through 60° of disc rotation.

Comment: Some special designs can effectively operate from 15 to 75 degrees of disc rotation.
Control Valve Cv Calculation

ADNOC AGES-SP-04-002:

Control valves shall be sized for a minimum fully open capacity of 110% of maximum flow. The
selected valve shall normally be less than 90% open for maximum flow and more than 10% open at
minimum flow, or shall be within the VENDOR’S minimum throttling Cv recommendation.

Butterfly valves shall be sized for a maximum flow at 60° angular opening, except for a
characterized vane valve (such as the “Fishtail”) which may be sized at 90° angular opening. Three-
way valves shall be sized to pass maximum flow through either port with minimum available
pressure drop through the same port.

ADMA-OPCO SP-1070 2008:

The maximum Cv shall be calculated by increasing the maximum operating flow by 15%. The
minimum opening of the control valve shall not be less than 15% of the full stroke at minimum flow
conditions. The maximum opening shall not be more than 70% at nominal flow conditions.

JGS STD-09-051 2003:

Required Cv will generally be twice the calculated Cv for the normal flow. The Cv for the selected
valve will be next larger Cv value than the required Cv. Lift ratio of the control valve will preferably
be between 50% - 70% for the normal flow conditions.

It is better to maintain the lift ratio over 10% for the minimum flow conditions, taking higher
pressure drop than those in normal conditions into account.
Control Valve Cv Calculation

Webinar: Control Valve Sizing and Selection - Fisher Technology Quick Talk:

In order to prevent poor installed gain characteristics into the process control system, the calculated
control valve sizing coefficient, Cv, should fall between the following travel ranges:

• Butterfly valves: 25% to 45%

• Segmented ball valves: 20% to 60%
• Plug-style rotary valves: 20% to 65%
• Ball valves: 20% to 65%
• Sliding-stem valves: 15% to 85%

Control Valve Sizing by Jon Monsen:

Control valve that is sized to operate around 60% to 80% open at the maximum required flow will
give the best control. To avoid potential control problems at the low end of the control range the
valve opening should not be much less than 20% whenever possible.

• Properly sized full ball, segment ball (“V” notch) and high performance butterfly valves are
usually two sizes smaller than the line.
• Properly sized globe valves are usually one size smaller than the line.
Control Valve Cv Calculation

INSTRUMENT ENGINEERS’ HANDBOOK Fourth Edition 2006:

One should first determine both the minimum and maximum Cv requirements for the valve,
considering not only normal but also start-up and emergency conditions. The selected valve should
perform adequately over a range of 0.8 Cvmin to 1.2 Cvmax. If this results in a rangeability
requirement that exceeds the capabilities on one valve, use two or more valves.

Maximum flow of the linear valve should not exceed 60% and maximum flow of the equal-
percentage valve should not exceed 70% of the maximum flow through the valve. In terms of valve
lift, these flow limits correspond to 85% lift for equal-percentage and 70% lift for linear valves.

Another important rule is to make sure that the maximum required flow capacity for the valve does
not exceed 85% of the valve’s maximum rated capacity. This is because there is a typical tolerance
of ±10% between what is advertised as the maximum Cv number and what actually is the Cv of the
particular valve.

Similar rules apply to the minimum required flow coefficient, which is obtained by considering a
process condition when the flow is the minimum and the valve pressure drop is the maximum. Once
this Cvmin is determined, one has to make sure that the valve travel at the required minimum flow
coefficient is not less than 10% of the rated travel (or twice the expected dead band of the valve,
whatever is higher) away from touching the valve seat. This safety margin is necessary to make
sure that the plug does not touch the seat during any excursion caused by a disturbance in the
control loop. If the minimum flow capacity of the larger valve is insufficient to provide the required
rangeability for the loop, use two valves in parallel by split-ranging the control signal among them.
Control Valve Cv Calculation

ExxonMobil IP 15-9-1 1998:

Control valve sizing shall comply with the following criteria:

a. Valve size shall be the smallest one that meets the requirement that its flow coefficient is equal
to or greater than 125% of the flow coefficient calculated from the design flow rate and
conditions, taking into account the effect of piping configuration such as changes in line size.

b. Control valve size shall be selected so that the minimum specified flow shall result in a stem
position of at least 20% of maximum lift (travel). In addition, the maximum specified flow shall
result in a stem position of no greater than 90% of maximum lift for an equal percentage valve
and 85% of maximum lift for a linear valve.

Conventional butterfly valves shall be sized for maximum angle opening of 60 degrees. Proposals to
use angles greater than 60 degrees shall be submitted for approval by the Owner's Engineer.

BP GP 30-35 2002:

Valves shall be sized so normal operation is between 15% at low flow and 80% at maximum flow.

If a flow efficient disc is used for butterfly valves, the valve should be sized with maximum flow rate
at 80 degrees open. If a conventional disc is used, maximum flow rate shall be limited to 50 degrees
open.
Control Valve Cv Calculation

IPS-E-IN-160 2015:

The control valve shall be sized such that the Cv value of the control valve for maximum process
flow with the pressure drop across the control valve at maximum process flow is approximately 80%
of the maximum Cv value for that control valve. Furthermore, the control valve shall never have less
than 25% lift for minimum process flow at the specified pressure drop.

If neither a maximum nor a minimum process flow is stated, these flows shall be assumed to be
120% and 80% respectively of the normal process flow.

Butterfly valves shall be sized for maximum angle operating of 60 degree at maximum flow.
Proposals to use angles greater than 60 degrees shall be submitted to the Company for approval.

NIOEC-SP-00-50 2017:

The calculated Cv shall be determined based on the following conditions:

• Minimum flow: Quantity at minimum flow while valve DP calculated for minimum flow conditions.
• Normal flow: Quantity at normal flow while valve DP calculated for normal flow conditions.
• Maximum flow: Quantity at maximum flow (whatever determined by process requirements but
not less than 10% higher above normal flow) while valve DP calculated for maximum flow
conditions.

The selected Cv shall be such that the valve opening is approximately at 75% of full opening at the
maximum value of calculated Cv. The valve should never have less than 25% opening at minimum
flow.
Thanks for your attention