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Control Valve Thumb Rule Calculation
Control Valve Thumb Rule Calculation
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Butterfly Ball Globe Severe service
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versatile
often used in slurry flows
provide speed of operation
up to 4” diameter line
fully open/closed by ¼ turn
expensive
small pressure drop (straight through hole)
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provide almost full flow
minimum turbulence and fluid trapping
minimal pressure drop
used where operation is infrequent
100% seal
packing wears out, high maintenance
atmospheric leaking
threaded stem, more cumbersome to open
never used for throttling
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used most often for
throttling or
modulation
disc and seat
material must be
compatible with
fluid in service
inexpensive, but
high pressure drop
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fully open/closed with ¼ turn
best suited to low pressure, low flow service
sediment buildup usually minimal (due to
narrow body design)
installed in up to 48” pipe
no packing to wear out, no atmospheric
leaking
not a positive seal except on water or steam
lines
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prevents backflow by automatically seating
when flow direction reverses
three basic types: swing, lift, and ball
fluid velocities should generally be low and
nonpulsing
installed as far as possible from pumps
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severe service = high pressure drop = high velocity = enemy
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Lost Trim &
production body wear
System Pipe
shutdown vibration
Poor Downstream
control pipe erosion
Noise High
maintenance
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Erosion &
cavitation
Vibration
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Wellhead pressure control
High pressure let down
Overboard dump applications
Fire water pump discharge
High rangeability applications
Gas treating
Methanol injection
Import / export valves
Cavitation / flashing service
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Rich amine letdown
Lean amine pump recycle
Expander bypass (JT valves)
Emergency depressurizing
Auxiliary power unit valves
Import / export gas regulation
Compressor anti-surge
Hot gas bypass
Process gas to vent / flare
Slug catcher / knockout drum level
control
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Feed gas regulator
Slug catcher level control
Amine pump recirculation control
C3 / MCR / BOG compressor anti-surge
control valves
Gas-to-flare
Depressurizing
Rich amine level control
Hot gas bypass valves
MCR / Feedgas JT (Joule-Thomson) valves
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Compressor station Metering station valves
◦ Compressor recycle ◦ Pipeline regulator
◦ Emergency vent ◦ Active / monitor
◦ Inlet / outlet pressure
control ◦ Slave / master valves
◦ Vent silencers
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Pumping station
◦ Pump recycle
◦ Export flow control
◦ PIG launcher pressure control
Pipeline pressure reducing station
◦ Pressure letdown
◦ Surge relief
Oil terminal
◦ Pressure letdown
◦ Metering station
◦ Tanker fill / flow control
◦ Vapor recovery systems
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Feed gas flow regulator
Compressor anti-surge
Steam vent
Lean amine pump recycle
Rich amine letdown
Expander bypass
Process gas depressurizing
Gas to vent / flare
Auxiliary power unit valves
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Hydrocracker unit
◦ Flash gas relief
◦ Make-up gas compressor recycle
◦ HP / HT oil letdown
◦ Feed oil surge relief
◦ Vent & pressure control
Hydrotreater unit
◦ Recycle gas compressor anti-surge
◦ Hot & cold separator level control
◦ Feedstock pump recycle
◦ Separator vent & pressure control
Auxiliary steam unit valves
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Hydrogen unit
◦ Process gas to vent / flare
◦ Compressor anti-surge recycle
◦ Lean amine pump recycle
◦ Rich amine letdown
Catalytic cracker
◦ Air compressor anti-surge
◦ Flue gas expander bypass valve
H2S / CO2 stripper loops
◦ Rich amine letdown
◦ Lean amine pump recycle
◦ Sour water letdown
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A CV is operated by an automated actuator to
maintain a process variable at a set point. A CV
consists of the body, bonnet, packing, trim, &
actuator assembly.
Actuators come in many types. Typical ¼˝ valve
actuator:
◦ is pneumatically operated, spring opposed
◦ operates in response to a 12 psi range change in instrument
signal
◦ full range signal change causes the valve to stroke a distance
of about ½”
◦ standard spring has a deflection rate of 25 lbs per 1/8”
◦ spring operates against a diaphragm with an effective area of
7½”
◦ can be operated as air-to-close (ATC) or air-to-open (ATO)
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High pressure drops
Two-phase flows
Erosion
Wear
Vibration
Noise
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A control valve trim refers to the inner
valve set consisting of the plug, stem
and seat. The trim is the device that is
positioned in the flow path to adjust
rates. The selection of valve trim size is
a key element in obtaining a control
valve that will provide stable operation in
the process.
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bonnet
valve body
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Calculate trim
coefficient
C V, liq FL
P FL liquid flow rate (gpm)
FG gas flow rate (SCFH)
FG T ½ FS steam flow rate (PPH)
C V, gas sp. gravity relative to air or water
1360 P1 P P pressure drop (P1 - P2, psi)
P1 upstream pressure (psia)
FS
C V, steam P2 upstream pressure (psia)
63 P V V sp. volume of upstream steam
T temperature
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Compare calculates
trim coefficient to
manufacturer’s
selection chart
Shown is the trim
size chart of Badger
Valve (Tulsa,
Oklahoma)
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Single stage pressure
drop
P = P1 - P2
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Multi stage pressure
drop
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Single stage pressure Multi stage pressure
drop drop
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flashpoint
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Acceptable energy Acceptable velocity
gas / steam liquid / water
Location Psia ft / sec
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P Fluid velocity vs. stages Recommended
of pressure drop velocity / turns
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Single stage pressure Multi stage pressure
reduction reduction
flow
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Prescribe the minimum mandatory requirements
governing the design, sizing & selection of control
valves
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Buyer shall specify plant operation: daily start &
stop, weekly start & stop or base loaded
Buyer shall specify process data for normal
flow, max flow & min flow
Buyer shall provide process conditions which
define the performance requirement of the
control valve
Benefit: Defines plant operating requirements
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Supplier’s basic responsibility:
1. Meet pressure boundary requirements
2. Meet max flow capacity at 80 – 95% travel
Suppliers performance responsibility:
1. Demonstrate control of trim exit kinetic energy
to specified limits
2. Confirm methodology & meet noise requirements
3. Provide seat forces noted to meet leakage
requirements
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1.0 Kinetic energy (velocity head)
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2.0 Pressure reducing stages
◦ Supplier shall provide sufficient number of discrete
pressure drop stages to insure the elimination of
abrasion, erosion, & vibration
◦ Supplier shall identify the number of pressure drop
stages in proposed equipment
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Trim outlet kinetic energy criteria
V2 Gas / steam kinetic Equivalent liquid
KE = energy criteria / water velocity
2gc
Service conditions Psia ft / s
Continuous service single 70 100
phase fluids
Cavitating & multiphase 40 75
fluid outlet
Vibration sensitive system 11 40
Intermittent duty 150 -
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1.0 Trim exit velocity
◦ For liquids velocity shall not exceed 100 ft/sec (30
m/sec)
◦ For flashing & cavitating, service velocity shall not
exceed 75 ft/sec (22.5 m/sec)
◦ Supplier shall provide calculation demonstrating
meeting the above velocity requirements
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2.0 Pressure reducing stages
◦ Supplier shall provide sufficient number of discrete
pressure drop stages to insure the elimination of
abrasion, erosion, vibration, & cavitation
◦ Supplier shall identify the number of pressure drop
stages in proposed equipment
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3.0 Application
◦ Application of velocity head criterion allows higher
fluid velocities for less dense fluids & conversly
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4.0 Noise
◦ Noise shall be calculated in accordance with
methodology outlined in ISA SP75.17 & IEC 534-8-
3 guidelines
◦ The max noise levels shall have an upper tolerance
of +0 dBA
◦ Seller shall be required to include inaccuracies &
guarantee that the noise level, including upper
tolerance, shall not exceed specified noise level
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Noise generated by diffusers or orifice plates
shall be calculated as a separate system from
the valve trim & included in the overall noise
level
A max of 5 dBA credit may be used for the
application of insulation for noise reduction
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5.0 Seat leakage
◦ Min seat leakage class (ANSI/FCI-70-2) will be IV or
V, depending on application requirement
◦ MSS-SP61 (block valve) leakage class specified for
control valves normally shut during operation
Benefit: Prevents seat leakage degradation
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Class IV – 300 lb/in (5.4 kg/mm)
Class V – 500 lb/in (8.9 kg/mm)
Class MSS SP61 (block valve)
◦ For less than 3000 psi (21 Mpa) – 1000 lb/in
(8kg/mm)
◦ For greater than 3000 psi (21MPa) 1500 lb/in (27
kg/mm)
Force is that per linear seat ring circumference
Seller to provide detailed calculation of seat load
Benefit: Prevents seat leakage degradation
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to R-201 from R-201
5 6
TIC
E-202
Explain the operation of the reactor
feed heat exchanger in the DME
Process
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to R-201 from R-201
5 6
How would this system respond to
TIC
fouling in the heat exchanger or to a
E-202
loss in catalytic activity in R-201?
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to R-201 from R-201
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to R-201 from R-201
5 6
TIC
Feedback Control
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to R-201 from R-201
5 6
TIC
E-202
Design a control system that would
regulate the exit temperature T6 rather
than the inlet temperature T5.
4 7
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to R-201
5
from R-201
E-202 6
Design a control system that would
regulate the exit temperature T6 rather
than the inlet temperature T5.
TIC
Direct Method – move bypass to inlet.
7
This method gives us the further
advantage of being able to directly
control the conversion in the reactor
since T6 is a direct indication of
4 conversion.
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R-901
• liquid phase, exothermic reaction
• feed in stream 1 is known to vary
• heat of reaction removed by E-901
Regulate
TIC
outlet temperature
1 R-901 Regulate
FIC LIC
cw reactor inventory
E-901
Compensate for a
change in flowrate
P-901 A/B
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R-901
• liquid phase, exothermic reaction
• Hrxn partially vaporizes contents
• Vapor condensed in E-901 and returned to R-901
• R-901 operates at boiling point of contents
TIC
Regulate
E-901
reactor temperature
LIC
1 R-901
Regulate
reactor inventory
FIC LIC
Compensate for a
change in flowrate
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Distillation column control systems -
◦ designed to produce a product stream
which has a specified composition and
neither exceeds nor falls short of this
mark (maintain quality specifications)
◦ assure column operation remains within (2) LC (1)
the operating limits
◦ prevent flooding, slugging, excessive
weeping, and dumping TC
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columns w/ total condensers,
rate of vapor condensation adjusted
by
◦ 1. changing condenser cooling flow
(fouling when water temps exceed 50°C)
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columns w/ total condensers,
rate of vapor condensation
adjusted by
◦ 2. injecting noncondensable gas into
overhead (can effect temperature PC inert
of top trays; may be necessary to gas
vent;
results in containment issues
and product loss)
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columns w/ total condensers,
rate of vapor condensation
adjusted by
◦ 3. bypassing
inert vapor around the
condenser
PC
gas PC
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columns w/ total condensers,
rate of vapor condensation adjusted
by
◦ 4. using a flooded condenser
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24 possible configurations of the 3
loops and 1 free variable
many dismissed quickly (i.e., loop
includes entire column between
controlled variable and manipulated
variable - large time delay and large
in transfer function sluggish
operation)
8 possible acceptable configurations
(2 non-conventional)
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LC
LC
TC
TC
LC LC
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LC LC
standard TC
configuration
TC
LC LC
initial action taken to control composition manipulates the internal recycle flow by changing the
reflux rate or the reboiler duty, which changes the boil-up rate. Subsequent actions by other loops
affect overall material balance of column.
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LC LC
TC
TC
LC LC
one product stream is set as the “free” variable, the other is placed on level control to maintain the
column material balance. Deviations from quality specs are corrected by manipulating the
internal bulk flow rates within the column.
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THANKS