Workshop NotesModulating Control Valve

Sizing and Selection

R

CONTROLS

Workshop  Notes:  Modulating  Control  Valve  Sizing  Selection    

BraySize  BII  Sizing  V2.0.1  Dated:    06/Jan/2014    

Roger  Barnes  -­‐1/20/2014    

1. Open  Program  –  select  new  project  XXXX  Workshop  Jan  xx  2. Demo  –  Project  settings  

a. Affects  the  next  line  item  valves  only,    not  the  currently  opened  line  item    i. Default  units  (metric  &  Imperial  can  be  mixed,  individual  line  items  can  be  

different  )  ii. Degree  or  %  of  stroke    

1. Min/Max  setting,  only  sets    warnings  level  a. 20  to  80  %  or  degrees  good  starting  point    

iii. Noise  warning  limit  (suggest  90)  3. Demo  assigning  tag  line  item  

a. Select  line  item  b. Select    “revision/Item  info  (lower  left)  c. Enter  Item  information  

 

d. Click  “item”,  then    “Save”  (menu  bar  or  highlight  item  right  click)  

 

4. Enter  process  data  for  Example  (approximate  conditions  from  “real  world”  examples    from  module  6  Flow  Characteristics,  water,  10”  line)  press  “calculate”  

 5. Demo  change  in  Shut  Off  ΔP  &  Design  Press  –  Impacts  actuator  only  

a. Note  Following  i. Shut  off  ΔP  –  defaults  to  the  highest  P1    ii. Impacts  actuator  sizing  only    

1. Change  to  150  psi  2. Note  that  it  changes  Design  pressure,  Can  still  select  a  Series  21  for  

example  

   

6. Demo  design  pressure    a. Design  Pressure(and  Design  Pressure)  –  defaults  to  highest  P1  or  shut  off  

i. Impact  valve  pressure  class  selections  ii. Change  to  151  psi  iii. Now  cannot  select  S21  only  S31  iv. Note!  If  you  change  service  conditions  these  values  do  not  reset  

automatically  –  must  be  done  manually      

 7. Explained  “Valve  Selection”  (power  point  slide  #  7)  

a. “Selection  Criteria”  is  a  filter  b. BraySize  defaults  to  line  size  valve  (not  always  the  best  choice)  

8. Try  Select  10’  S21,    Click  “Re  Calc”  (PP  slide  #8)  Note  now  red  “Re  Calc”  not  “Calculate’  a. Note  red  %  “opening  degree”  warning  

 

9. Check  flow  curve  –  Click  “item”  (menu  bar),  “Flow  curve”  a. Operating  too  close  to  seat  

i. 20%  is  rule  of  thumb  not  a  hard  fast  rule  

 10. Try  smaller  8”  (better  control)  –    

a. Red  warning  gone  

 

b. Check  flow  curve,  click  “Item”,  “Flow  Curve”……But….    i. Note:  The    “red  light”  on  Material,  It  is  preventing  you  from  going  father  

1. Green  =  Go,  everything  on  that  scree  is  OK  2. Yellow  =  Something  has  been  overridden  (non-­‐standard  positioner,  

solenoid  etc.,  does  not  mean  ‘caution’)  3. Red  =  Warning  or  attention  required    (red  on  sizing  because  of  

cavitation  warning)    ii. Program  requires  you  to  ‘validate  materials’  when  valve  size  or  type  is  

changed  –  click  “material”  and  go  back  to  Sizing  and  selection.  1. Just  to  insure  the  correct  material  are  still  selected  (effects    

 

c. Marginally  better  flow  curve  i. Which  is  better  –  either,  or  quote  both  

1. One  size  smaller  than  line  size  is  the  rule  not  the  exception  for  modulating  control  valves    

2. 10”  does  not  require  reducers  3.  8”  marginally  better  modulating  control  (its  job  is  to  create  a  

pressure  drop)  a. Less  expensive  valve  actuator  package  

i. Less  than  cost  of  reducers???  

   

 11. What  about  cavitation  warning  ????-­‐Cavitation  application  is  both  a  Science  and  Art  

a. Lots  of  factors  affect  decision  –  Warning  might  not  mean  there  is  a  problem  i. Startup  condition  only?  

1.  Might  be  Ok  but  probably  not  if  continuous  operating  point  (damage  is  time  dependent,  short  term  exposure  is  OK  )  

ii. Cavitation  calculation  very  very  sensitive  to  P2  1. Change  P2  from  6  to  7,  one  psi  change  is  enough  switch  off  the  

warning.  Ask  customer  to  verfy  P2  iii. Change  P1  from  20  to  18    

1. Cavitation  less  sensitive  to  P1  (required  2  psi  change)  iv. Double  check  temperature  (cavitation  sensitive  to  high  temp)    

1. Make  sure    using  actual  operating  temperature  not  max  design  temp  

   

12. Try  a  ball  valve  to  solve  Cavitation  problem  a. Left    click  on  line  item,  select  “Duplicate”  

i. Keeps  process  data  and  valve  selections  b. Change  Brand    to  FlowTek  

i. Keeps  Service  Conditions,  defaults  everything  else.  

 

c. Change  item  tag  to  “Alternate  Ball  Valve”  i. Click  Revision/Item  Info  ii. New  line  number  but  same  tag#  

 13. Try  Round  Port,    FR-­‐15,  8”  Standard  Port,  

a. Cavitation  Issue  Solved!!!!  i. (But  now  a  max  capacity  problem)  ii. Note  Calculated  Cv  has  been  different  for  the  three  different  valves  we  have  

selected!!!  -­‐-­‐-­‐-­‐  1. Impact  of  FL/FP/FLP:  Smaller  than  line  size  valve  require  more  Cv!    

a. Initial  “Estimated  Cv”  =2472  b. “Calculated  Cv”  10”  BFV  =  2472  c. “Calculated  Cv”  8”  BFV  =  3073  d. “Calculated  Cv”  8”    Standard  Port  Ball  =  2709  e. “Calculated  Cv”  8”    Full  Port,  Ball  =  3037  

b. Try  a  Full  Port  Ball  –  Max  flow  ok  but  %  open  issue,    c. Try  S19  -­‐  Cavitation  issue  back  (only  one  stage  pressure  drop)    

   

14. Go  back  to  Power  Point  slides  9  thru  13  to  discuss;  two  pressure  drops  in  series  to  control  and  Cavitation,  explain  different  Cv  by  size  and  valve  type  

a. Round  Port  has  two  Pressure  drops  in  series  b. V-­‐ports  not  as  effective  c. S19  Segmented  ball  has  only  one  drop  

15. Size  two  BFV  in  series  (each  ½  drop)  to  achieve  same  results  a. Same  result  as  Ball  Valve  (full  ball  only)  b. Both  must  on  the  same  control  signal  

16. Demo  that  basic  fluids  can  be  modified  (10”  Standard  Port,  Round  Port  Ball)  a. Example  change  SG  (specific  gravity)  to  1.5  (example  slurry)    

i. Calculated  Cv  Changes  from  2472  to  3031    1. Factor  of  1.2247  ( 1.5    change  of  sg)  

b. Could  do  the  same  modification  on  Pv,  Pc,  and  viscosity  

 

17. Demo  Actuator  Sizing  a. Will  BraySize  2.0.1  Beta  will  size  both  S98  and  S92/93  

i. Not  yet  publicly  released  (S98  Data  sheet  display  issues  to  resolve)    b. Default  Factor  of  safety  =  1  c. Calculate  both  “Basic”  (=Break  out)  torque  and  d. Dynamic  (modulating)  torque,  can  be  higher  than  break  out  with  high  throttling    ΔP  

i. Sizes  based  on  worse  case  e. Total  Torque  =  Basic  Torque  X  Factor  of  Safety  

 f. Rack  &  Pinion,  S92/93  

i.  Fail  closed  or  Open    

g. Scotch  Yoke  S98    i. Note!  Warning  that  size  selected  may  not  be  in    current  range      

 

   

18. Dem  accessories  a. Note!!!  Interface  will  not  prevent  you  from  making  mistakes  

i. Cannot  have  a  positioner,  Namur  solenoid,    etc.    

 

19. Demo  “Factory  Notes”;  Standard  pre-­‐loaded  and  custom  notes    20. Demo.  “Item”,  “Compare”  feature:    

a. Compare  Revisions  of  any  one  line  item  i. Compare    line  items  with  each  other(Ball  to  Ball  V;  BFV  to  BFV’s  Only  

21. Demo  “Report”  Builder-­‐  Generates  ISA  style  Control  (modulating)  Valve  data  sheets  (see  appendix  or  work  Book)  

a. Click  “Reports”,  “Print  Reports”,  Select  file  location,    i. Generates  PDF  ISA  style  data  sheets:  Be  patient    

1. Process  Data,  Valve  Data,  Actuator  and  Accessories  sheet  2. Valve  Calculation  Sheet  3. Actuator  Sizing  Sheet  

 

 22. Demo  Back  Calculation  (Using  S21,  8”  RBFV)  

a. Bray  Size  can  ‘back  calculate’;    i. Flow  for  given  Cv  and    Pressures  for  a  given  Cv  ii. Pressures  (drop)  for  given  Cv  and  Flow  

b. Answers  customer’s  “What  if  Questions”    c. Flow  Calculation  steps  

i. Remember  or  record  “Rated  Cv”  ii. Select  “Calculation  –  Flow”  (lower  left)  Note  Flow  Changes  to  Cv  on  service  

conditions    iii. Enter  Cv,  Click  “calculate”,  Note  “new  flow”  appears  in  service  conditions  

d. Similar  Process  for  pressure  calculations

 

23. Solving  for  Δ  Pressure;  Select  “P1”,  enter  valve  Cv,  Press  Recalculate,    ΔP  sovled  for    

     

 

               

                         

 

 

 

VALVE SPECIFICATION SHEET

1314

1112

1718

1516

10

45

23

89

67

Flow Rate (Liquid) gpm (US) 500 1000 1500 3500Inlet Pressure psig 20 16 14 12 150

Inlet Temperature °F 70 70 70 70Outlet Pressure psig 6 7 8 10

Design Press. (Max.) psig 150Design Temp. (Min. / Max.) °F 33 / 100

Choke Drop psid 22.446 21.406 19.188 15.339Pressure Drop psid 14 9 6 2

Noise (Allow / Predict) dBA < 70 < 70 < 70 < 70

Velocity WarningOutlet Velocity ft/s 2.034 4.069 6.103 14.24

Travel Deg 21.6 34.8 46.4 77.4

Sp. Gravity 0.998 0.998 0.998 0.998Viscosity cP (CentiPoise) 0.976 0.976 0.976 0.976

Flow Warning Cavitation

Calculated Cv 133 333 618 3037Vapour Pressure psig -14.33 -14.33 -14.33 -14.33

Units Min Norm 1 Norm 2 Max Shut-OffProcess Fluid Liquid / Water Phase Single psigCritical Press. Pc 3193.3929

Sheet 1 of 3

353637

323334

414243

383940

31

222324

192021

282930

252627

1

Date :

Project UK #2 Sizing Item # #1-[2] FCV 01 ExampleEnquiry Ref. Application Bray SchoolQuotation # Function Control

Customer Tag # FCV 01

Size / Rating Standard 8" / ASME Max. Allow. Pressure 120 psigRating CL 125/150 Min. Req. Pressure 40 psigPressure Rating Full Pressure rating Min. Avl. Air Pressure 80 psig

In Pipe Size / Sch. 10 in / STD Actuator Type Pneumatic - Spring Return (Rack & Pinion)Out Pipe Size / Sch. 10 in / STD Mfr. / Model Bray / Series - 93Valve Type Resilient Size / No. of Spring 160 / 5

Body Seal N/A L. Sw. Type / Contacts Proximity (Non-Contacting) / SPDTLiner N/A L. Sw. Rating / Pos'n IS / Open

Seat Type Soft Air. Mfr. / Model / Range Bray-Series 55 / 0 – 125 psigSeat Material Teflon/EPDM (Standard) Pos. Indi. Mfr. / Model None

Rated Cv 5191 Solenoid Type / Vol. None

NACE Compliance No Volume Booster BrayLeakage Class Bubble Tight Shut Off

Flow Characteristics Equal Percentage Air Lock Valve NoneFire Safe Valve N/A Volume Tank Bray

Stem Packing N/A Certification None

Extension Bonnet N/A Act. Orientation PerpendicularEnd Connection Lug Manual Override No

Valve Series Series 21 Max. Avl. Air Pressure 120 psigBody Material St. Steel, ASTM A 351 Gr CF8M Fail Action Close

Flg. Face Type / Finish N/A Pos. Mfr. / Model Bray-Series 6A

Disc SS 316 Gauges YesStem SS 316 Signal Action Direct

Flow Direction Bi - directional Pos. Type Electro PneumaticBody Bolting B8 / Gr 8 Input Signal 4 - 20 mA

606162

575859

666768

636465

56

474849

444546

535455

505152

22/01/2014Version : V2.0.1 Date : 06/01/2014

987

10

131211

2 Export Crating 0 Roger Barnes 21.01.141 Demo Valve for Control Vave Sizing Work Shop Rev. By Date

Notes Revisions

3 Basic Outline Drawing 1 Roger Barnes 22.01.14

6 Visual / Dimensional Report5 Standard Factory Tests4 Hold Point to Witness Test/Inspection 2 Roger Barnes 22.01.14

VALVE SIZING CALCULATION SHEET

Enquiry Ref. Application Bray SchoolQuotation # Function Control

Customer Tag # FCV 01Project UK #2 Sizing Item # #1-[2] FCV 01 Example

Downstream Pipe Size (in) 10 10 10 10Downstream Pipe Schedule STD STD STD STDValve SPL (dBA) < 70 < 70 < 70 < 70

Noise CalculationValve Type Butterfly Butterfly Butterfly Butterfly

Valve Velocity (ft/s) 3.191 6.383 9.574 22.34Outlet Velocity (ft/s) 2.034 4.069 6.103 14.24

VelocityInlet Velocity (ft/s) 2.034 4.069 6.103 14.24

Sizing Coefficient, Cv 133 333 618 3037Pressure Drop (psid) 14 9 6 2

SERVICE AND SIZING Min Norm 1 Norm 2 Max

dP Choked (psid) 22.4459 21.4058 19.1881 15.3389

Cavitation Index, Kc 0.408 0.297 0.212 0.076

Specific Gravity 0.998 0.998 0.998 0.998Vapour Pressure (psig) -14.33 -14.33 -14.33 -14.33

Pressure Recovery Factor, FL 0.808 0.837 0.815 0.647Temperature (°F) 70 70 70 70

Inlet Pressure (psig) 20 16 14 12Process Fluid Name Water

Liquid Flow (gpm (US)) 500 1000 1500 3500Outlet Pressure (psig) 6 7 8 10

Valve Diameter, d (in) 8" 8" 8" 8"

Outlet Pipe Diameter, D2 (in) 10.75 10.75 10.75 10.75Inlet Pipe Diameter , D1 (in) 10.75 10.75 10.75 10.75

Combined Recovery Factor, FLP 0.808 0.837 0.815 0.647Valve Style Modifier Factor, Fd 0.356 0.414 0.466 0.542

Critical Pressure Ratio Factor, Ff 0.957 0.957 0.957 0.957Piping Correction Factor, Fp 0.999 0.997 0.989 0.81

Item Description Series 21, 8", CL 125/150, Lug

Cv 11.7 87.4 202.6 353.8 570.5 887.2 1383.4 2228.4 3580.9 5191Travel Deg 9 18 27 36 45 54 63 72 81 90

Rated Cv: 5191

Flow Char: Equal Percentage

Valve Series : Series 21

Valve Size: 8"

Sheet 2 of 3Version : V2.0.1 Date : 06/01/2014

C - (46.4,618)

D - (77.4,3037)

Degree Opening, Calculated CvA - (21.6,133)

B - (34.8,333)

Date : 22/01/2014

ACTUATOR SIZING SHEET

Pneumatic End Torque (lbs-in) 1825 lbs-in

Manual Override NoActuator Model & Size Series - 93 & 160

Fail Safe Condition Fail Close

Max. Available Supply Pressure (psig) 120Actuator Type Pneumatic - Spring Return (Rack & Pinion)

Pneumatic Start Torque (lbs-in) 3502 lbs-in

Valve Model Series 21

Spring End Torque (lbs-in) 2240 lbs-in

No of Spring 5Spring Start Torque (lbs-in) 3917 lbs-in

Maximum Inlet Pressure (psig) 20Maximum Pressure Drop (psid) 14

Temperature (°F) 100

Valve Size (in) 8Media Water

Shut off Pressure (psig) 150

Torque with Safety factor 2190Min. Available Air Supply Pressure (psig) 80

Safety Factor 1.2

MAST (lbs-in) N/ABasic Torque (lbs-in) 1825

Sheet 3 of 3Version : V2.0.1 Date : 06/01/2014

2240 lbs-in

3917 lbs-in

1825 lbs-in

3502 lbs-in

Date : 22/01/2014

ACTUATOR SIZING

Item Description Series 21, 8", CL 125/150, Lug, Pneumatic - Spring Return (Rack & Pinion), Series - 93

Enquiry Ref. Application Bray SchoolQuotation # Function Control

Customer Tag # FCV 01Project UK #2 Sizing Item # #1-[2] FCV 01 Example

Notes:

R

CONTROLSWorkshop Notes1-22-2014