Professional Documents
Culture Documents
Valve Handbook
The Concise
Valve Handbook
Sizing and Construction
Volume I
Michael A. Crabtree
10 9 8 7 6 5 4 3 2 1
Research studies, within the process industry, routinely indicate that the
final control element is responsible for 60% to 70% of poor-functioning
control systems.
Although valves themselves are consistently wrongly selected,
regularly misapplied, and are often incorrectly installed, a large proportion
of the blame may also be attributed to a number of associated ancillaries:
the valve actuator, I/P converter, and positioner.
Levelled at anyone working at a technical level in the process control
industry, Volume I: Sizing and construction provides a total in-depth insight
into valve technology. While studying both liquid and gas valve sizing, the
guide also presents a methodology to ensure the optimum selection of type,
size, body and trim materials, components, and ancillaries—covering:
control valves, check valves, shut-off valves, and solenoid valves.
Volume II: Actuation, Maintenance, and Safety Relief, takes an
in-depth look at actuators and positioners. This volume also explores
a variety of maintenance and diagnostic issues including: testing for
dead-band/hysteresis, stick-slip and non-linearity; on-line diagnostics;
signature analysis; and correct procedures for calculating the spring
“wind-up” or “bench set.”
A complete section is also devoted to the whole field of safety relief
devices.
Lastly, this volume covers a number of topics which are all too
often ignored: acoustics; water hammer; and even classification of
stainless steel.
KeyWords
ball valves, butterfly and plug valves, cavitation and flashing, charac-
terization, construction, gas sizing, globe valves, leakage, liquid sizing,
material selection, noise treatment, trim
Contents
List of Figures xv
List of Tables xxv
Foreword xxvii
Volume I
1 Basic Principles 1
1.1 The Final Control Element as Part of the Control Loop 2
1.2 Basic Theory 3
1.3 Equation of Continuity 3
1.4 Bernoulli’s Equation 5
1.5 Choked Flow 8
1.6 Pressure Recovery 9
1.7 Turndown Ratio and Rangeability 11
1.8 Velocity Profiles 12
1.9 Reynolds Number 13
1.10 Flashing and Cavitation 14
1.11 Flashing 15
1.12 Cavitation 16
1.13 Leakage Classification 18
1.14 Isolation Valve Leakage Classification 21
2 Liquid Valve Sizing 23
2.1 Practical Considerations 23
2.2 Application of Formulae 24
2.3 Sizing Example 1 27
x • Contents
4.25 Ball Valve 75
4.26 Trunnion Ball Valve 77
4.27 Characterized Ball Segment Valve 81
4.28 Butterfly Valve 82
4.29 Plug Valve 84
4.30 Eccentric Plug Valve 86
4.31 Check Valves 88
4.32 Valve Sizes and Pipe Schedules 88
4.33 Material Selection 90
4.34 Corrosion 90
4.35 Erosion 94
4.36 End Connections 94
4.37 Screwed End Connections 94
4.38 Flanged End Connections 95
4.39 Hub End Body 96
4.40 Welded End Connections 96
4.41 Lap Joint Flange 98
4.42 Flangeless Connections 99
4.43 Grayloc® Connector 100
5 Valve Trim and Characterization 103
5.1 Inherent Characteristics 103
5.2 Linear Inherent Flow Characteristic 103
5.3 Equal Percentage Inherent Flow Characteristic 104
5.4 Quick Opening Inherent Flow Characteristic 104
5.5 Modified Percentage Inherent Flow Characteristic 105
5.6 Characteristic Profiling 105
5.7 Installed Characteristics 105
5.8 Cavitation Control 108
5.9 Reducing Cavitation 110
5.10 Eliminating Cavitation 112
5.11 Noise Sources 113
5.12 Mechanical Noise 115
5.13 Hydrodynamic Noise 116
xii • Contents
Volume II
7 Valve Actuators and Positioners 141
7.1 Pneumatic Control 141
7.2 Flapper–Nozzle Assembly 141
7.3 I/P Converter 142
7.4 Diaphragm Actuators 144
7.5 Springless Diaphragm 145
7.6 Advantages and Disadvantages of Diaphragm Actuators 147
7.7 Cylinder Actuators 147
7.8 Spool Block 149
7.9 Electro-Hydraulic Actuation 149
7.10 Electric Actuation 150
7.11 Torque Limiting 152
7.12 Hammer-Blow Mechanism 153
7.13 Solenoid Valve 153
7.14 Digital Actuators 155
7.15 Transfer Mechanisms 157
7.16 Valve Positioners 161
7.17 Positioner Guidelines 163
Contents • xiii
Figure 4.22. In the slab valve, the gate is pushed against the seal by
the flow pressure. 64
Figure 4.23. The moving section comprises a slab-shaped gate
with a single port drilled through it. 65
Figure 4.24. The expanding gate valve comprises two segmented
assemblies that are attached to each other by either a
spring or lever mechanism. 65
Figure 4.25. When the gate is in its final upper (open) position, with
the front segment against the upper stop, the lower back
angles are in contact with each other (courtesy Daniel
Valves).66
Figure 4.26. Exaggerated view showing how the opposing forces
cause the gate and segment assembly to expand, sealing
against both seats. 66
Figure 4.27. When the gate is in its final lower (closed) position,
with the front segment against the bottom stop, the
upper back angles are in contact with each other
(courtesy Daniel Valves). 67
Figure 4.28. Exaggerated view showing how the opposing forces
cause the gate and segment assembly to expand,
sealing against both seats. 67
Figure 4.29. The knife edge gate valve is an excellent valve for
service that requires either full or no flow. 68
Figure 4.30. The V-insert gate valve. 69
Figure 4.31. Flow/travel characteristics for different variations of
the sliding gate valve. 69
Figure 4.32. Sliding gate regulator valve makes use of slotted
movable disc and a stationary slotted plate (courtesy
Jordan Valve). 70
Figure 4.33. (a) When throttled open, the orifices of the disc align
with the openings of the plate to allow the required flow
to pass through the slots. (b) When the valve is closed,
the disc and plate form a solid barrier to flow (courtesy
Jordan Valve). 70
Figure 4.34. Sliding gate valve using a stationary plate and a
rotating disk. 71
Figure 4.35. (a) The pinch valve comprises a rubber hose, which
normally provides full flow. (b) When pinched together,
the flow stops. 71
List of Figures • xix
Figure 4.46. In the event that leakage past the seals does occur, and
in order to cater for double block-and-bleed a pplications,
a body vent allows the body cavity to be vented to
atmosphere. 79
Figure 4.47. (a) In its fully open position, the ball valve presents a
single circular orifice to the flowing medium. (b) As the
ball is rotated toward its closed position, the shape of
the opening changes to become two identical elliptical
orifices that offer two equal restrictions in series.
(c) Closed position. 80
Figure 4.48. Pathway fitted with parallel perforated attenuator plates
that produce a smooth gradual pressure reduction
across the valve that minimizes velocity, noise
generation, and cavitation (courtesy Neles-Metso). 80
Figure 4.49. Characterized V-notch ball valve in which the opening
between the ball and seal is modified to provide different
flow characteristics (courtesy Emerson–Fisher). 81
Figure 4.50. Different flow characteristics of the characterized ball
valve.81
Figure 4.51. Ball segment valve with centrally mounted shaft
(courtesy Somas Instrument AB). 82
Figure 4.52. Ball segment valve with eccentrically mounted shaft,
allowing pressure between the segment and seat to
be increased by increasing torque (courtesy Somas
Instrument AB). 82
Figure 4.53. Butterfly valve comprises a circular disc-shaped damper
mounted on a shaft. 83
Figure 4.54. Conventional center-disc butterfly valve. 83
Figure 4.55. Offset disc, or high performance butterfly valve. 84
Figure 4.56. (a) conventional disc shape (b) the fishtail disc
(courtesy Emerson–Fisher). 84
Figure 4.57. Flow characteristics of different-shaped butterfly discs. 85
Figure 4.58. Basic plug valve. 85
Figure 4.59. Camflex: eccentric rotary plug valve (courtesy
Masoneilan).86
Figure 4.60. Once seating occurs, a positive seal between plug and
seat is achieved by the elastic deformation of the plug
arms (courtesy Masoneilan). 87
List of Figures • xxi
Figure 4.61. In the hinged ‘swing check valve,’ the sealing disc is
attached to a hinge, which is free to rotate around the
hinge pin. 88
Figure 4.62. The pinch check valve feature: a typical 30-year
operational lifespan, a low headloss; they do not rust
or corrode; they are not affected by UV; and their
flexibility allows them to compress around trapped
solids (courtesy Tideflex). 89
Figure 4.63. Screwed end valve connections with tapered female
thread.94
Figure 4.64. Maximum pressure rating versus temperature for
carbon steel flanges (ANSI B16.5). 95
Figure 4.65. Flat-face flanged end connection. 96
Figure 4.66. The raised-face flange has a circular raised face. 96
Figure 4.67. Hub end or separable flange body. 97
Figure 4.68. Socket welding end. 97
Figure 4.69. Butt welding ends. 97
Figure 4.70. The lap joint flange is used in conjunction with a lap
joint stub end that is butt-welded onto the process
pipeline (courtesy Coastal Flange Inc.). 98
Figure 4.71. Flangeless valves are held between flanges by long
through-bolts.99
Figure 4.72. The Grayloc® connector comprises three components:
a metal seal ring, a two-part clamp assembly, and two
hubs (courtesy Oceaneering International). 100
Figure 4.73. (a) The clamp assembly fits over the two hubs and
forces them against the seal ring rib. (b) As the hubs
are drawn together, the seal ring lips deflect against
the inner sealing surfaces of the hubs (courtesy
Oceaneering International). 101
Figure 5.1. Inherent flow characteristics. 104
Figure 5.2. Quick opening flow characteristic uses a simple disc
shaped plug (courtesy Fisher Rosemount). 105
Figure 5.3. Plug outlines used to obtain (from left to right) equal
percentage; linear; and quick-opening flow
characteristic (photographs courtesy of Mitech). 106
xxii • List of Figures
Unit Conversions
Basic Principles
In any process control loop, the final control element is the mechanism
that changes the value of the manipulated variable in response to the out-
put signal from the control unit.
The final control element comprises the actuator, with its associated
and linkage and positioner, and the final control element proper—valve,
pump, transformer, motor, variable speed drive, and so on. It is axiomatic
that many of the problems associated with control loop performance can
also be laid at the door of the final control element.
Fluid properties can vary enormously from industry to industry. The
fluid may be toxic, flammable, abrasive, radioactive, explosive, or corro-
sive; it may be single-phase (clean gas, water, or oil) or multi-phase (e.g.,
slurries or dust-laden gases). The pipe carrying the fluid may vary from
less than 1 mm to many in diameter. The fluid temperature may vary from
close to absolute zero to several hundred degrees Celsius, and the pressure
may vary from high vacuum to high pressures.
Many different types of valves have been developed to suit these
variations in fluid properties and flow applications. However, only a few
valves have found widespread application, and no one single valve can be
used for all applications.
The basic purpose of a control valve is to control the flow of a medium
in a pipe, either turning it on or off or varying it continuously. However,
a control valve designed primarily to throttle energy is not necessarily
designed for shut-off purposes, and these two requirements often have to
be balanced or realized in separate systems.
Routinely, research studies within the process industry indicate that the
final control element is responsible for 60% to 70% of poor-functioning
control systems. The problems lie not just with the valve itself, but also
with the valve actuators, I/P converters, and positioners. However, prob-
ably the majority of problems can be attributed to oversized valves and
undersized actuators.
The first step in successful application is to gain an understanding
of the basics of a control system. As shown in Figure 1.1, the four basic
elements of any control system comprise:
• process;
• transducer (sensing element plus transmitter);
• final control element; and
• controller.
PV (%)
Kp = (1.1)
PD (%)
Controller
Process
Demand (PD)
Process
Variable (PV)
Process
Thus, for example, if we make a step change of 20% to the PD and the
PV also changes by 20%, then the process gain (KP) is 1. However, if the
PV only changes by 10%, then the process gain (KP) is 0.5. Alternatively,
if the PV changes by 60%, then the process gain (KP) is 2.
Generally, the process gain should lie between the 0.5 and 2.0. If it
is less than 0.5, then typically, the transmitter span is too wide for good
control. If the process gain is greater than 2, this is usually an indication
that the control valve is oversized.
1.2 Basic Theory
1.3 Equation of Continuity
V1 VVC V3
P1 PVC P2
Vena Contracta
∆P
Velocity
Distance
Distance
Figure 1.3. To allow the same amount of
liquid to pass the velocity must increase.
where:
v1 and v2 and A1 and A2 are the velocities and cross-sectional areas of the
pipe at points 1 and 2, respectively.
Basic Principles • 5
1.4 Bernoulli’s Equation
In its simplest form, Bernoulli’s equation states that, under steady flow
conditions, the total energy (pressure + kinetic + gravitational) per unit
mass of an ideal fluid (i.e., one having a constant density and zero viscos-
ity) remains constant along a flow line.
v12 P1 v 22 P2 (1.3)
+ = +
2 ρ 2 ρ
where:
v = velocity at a point in the streamline;
P = pressure at that point;
ρ = fluid density;
g = acceleration due to gravity;
z = level of the point above some arbitrary horizontal reference plane
with the positive z-direction in the direction opposite to the gravitational
acceleration; and
k = constant
In the restricted section of the flow stream, the kinetic energy (dynamic
pressure) increases due to the increase in velocity, and the potential energy
(static pressure) decreases.
Relating this to the conservation of energy at two points in the fluid
flow, then:
v12 P1 v 22 P2 (1.4)
+ = +
2 ρ 2 ρ
Multiplying through by ρ gives:
1 1
ρ .v12 + P1 = .ρ.v 22 + P2 (1.5)
2 2
or:
1 1
P1 − P2 = .ρ.v 22 − .ρ.v12 (1.6)
2 2
or:
1 1
∆P = ρ .v 22 − .ρ.v12 (1.7)
2 2
6 • The Concise Valve Handbook
where:
∆P = P1 − P2 (1.8)
Q
v1 = (1.9)
A1
and:
Q
v2 = (1.10)
A2
substituting in (1.7):
2 2
1 Q 1 Q
∆P = .ρ. − .ρ. (1.11)
2 A2 2 A1
Solving for Q:
2∆P
ρ
Q = A2 . 2
(1.12)
A
1− 2
A1
À.D 2
A1 = (1.13)
4
and:
π.d 2
A2 = (1.14)
4
to give:
2.∆P
π.d2
ρ
Q= . 4
(1.15)
4 d
1−
D
Basic Principles • 7
The term:
1
4
(1.16)
d
1−
D
2.∆P
Q = E v .d 2 . (1.17)
ρ
2∆P
Q = Cd .E v .d 2 . (1.18)
ρ
∆P (1.19)
Q = Cv
SG f
Q = flow rate;
CV = valve flow coefficient;
∆P = differential pressure (P1–P2); and
SG = specific gravity of fluid (water at 60°F = 1.0).
The valve flow coefficient, CV, is an index used to measure the capac-
ity of a control valve. CV is determined experimentally, using water as the
test fluid, for each style and size of valve with the valve either fully open
or at a given valve opening, usually stated as a percentage of maximum
travel.
Numerically, CV is defined as “the number of US gallons per minutes
of water at 60°F that will pass through a given flow restriction, with a
pressure drop of 1 psi across the valve.”
CV is thus an index that allows the liquid capacities of different
valves to be compared under a standard set of conditions. Table 1.1
compares the flow coefficient of a number of different types of valve at
different sizes.
8 • The Concise Valve Handbook
∆P
Q = 0.87 C v (1.20)
SG f
where the volumetric flow rate (Q) is expressed in m3/hr and the differen-
tial pressure drop (∆P) is expressed in bars.
1.5 Choked Flow
Equation (1.19) implies that, for a given valve, simply increasing the pres-
sure differential across the valve can continually increase the flow. In real-
ity, this relationship only holds true for a limited range. This is illustrated
in Figure 1.4 that shows a typical plot of actual flow versus √∆P through a
flow restriction. This indicates that flow is only proportional to √∆P within
the sub-critical flow region.
If the differential pressure is further increased, a point is reached
where no further flow increase occurs, despite increasing the differen-
tial pressure. This is termed as choked flow (also known as the crit-
ical flow) and is the maximum flow rate possible through that valve.
Decreasing the downstream pressure will not result in an increased flow
Basic Principles • 9
Sub-critical Critical
Choked flow
Incipient cavitation
Flow
Cv
∆P
rate, although the valve can handle the higher pressure drop with no
detrimental effects.
In gases, choked flow occurs when the velocity reaches the speed of
sound (Mach 1). For liquids, the speed of sound is extremely high, and
practically speaking, incompressible fluids do not choke. In practice, how-
ever, as the differential pressure is increased and the velocity increases,
the pressure at the vena contracta decreases. If the vena contracta pressure
falls to below the vapor pressure of the liquid, partial vaporization occurs
and the sonic velocity of the resultant liquid/vapor mixture falls dramati-
cally. At this point, choked flow occurs.
The practical consideration of choked flow is that, when calculat-
ing the CV required for a particular application, only the choked pressure
drop can be used in the formulae and not the actual pressure drop. This
results in a larger CV requirement than would otherwise be the case. If
choked flow is not taken into account, it is possible to select a valve that
is too small.
1.6 Pressure Recovery
the restriction, and therefore, less energy will be available downstream for
recovery to a higher pressure (Figure 1.5).
Alternatively, streamlined valves produce relatively higher veloci-
ties through their restriction than do less streamlined, restrictive valves.
Velocity, being inversely proportional to pressure, suggests lower pressure
at the vena contracta with high-recovery streamlined valves (Figure 1.6).
The amount of pressure recovery varies with valve style and stroke
and is a function of the upstream, vena contracta, and downstream pres-
sures. It is quantified by what is called the pressure recovery coefficient
FL—a dimensionless expression of the pressure recovery ratio in a control
valve that is mathematically represented as:
P1 − P2
FL = (1.21)
P1 − Pvc
P1
High recovery
Pressure
P2
Low recovery
PVC
Distance
P1
Pressure
Low recovery P2
PVC
High recovery
Distance
Table 1.2. Typical numerical values of FL for some different valve styles
Cage-guided Standard
globe globe Disk 60° Disk 90° Ball 90°
FL 0.9 0.85 0.75 0.5 0.6
FL2 0.81 0.72 0.56 0.25 0.36
where:
P1 = upstream pressure;
PVC = vena contracta pressure; and
P2 = downstream pressure.
Evaluation of the preceding expression suggests that high-recovery
valves will result in less pressure drop, P1–P2. Therefore, high-recovery
valves have a low value of FL, and low recovery valves have high values
of FL—where FL is always less than 1.0.
FL is determined by laboratory tests and cataloged by most valve man-
ufacturers for use in more precise determination of valve capacity during
critical flow. It also is useful in predicting damaging phenomena such as
cavitation. Some typical numerical values of FL are given in Table 1.2.
Note: FL is the ISA nomenclature and that sometimes the symbol Cf
is used. Fisher Rosemount formerly made use of the symbol Km where:
FL = K m (1.22)
1.8 Velocity Profiles
For a given pipe and liquid, as the flow rate increases, the flow of a
fluid will cease to be laminar and becomes turbulent. In turbulent flow, the
paths of the individual particles of fluid are no longer straight, but inter-
twine and cross each other in a disorderly manner so that thorough mixing
of the fluid takes place.
As shown in Figure 1.10, the velocity profile for turbulent flow is
flatter than for laminar flow, and thus closer approximates to the ‘ideal’ or
‘one dimensional’ flow.
1.9 Reynolds Number
ρ .V.D
Re = (1.23)
µ
where:
ρ = density of fluid (kg/m3);
µ = viscosity of fluid (Pa.s);
v = mean flow velocity (m/s); and
D = diameter of pipe (m).
In practice, the Reynolds number is a ratio of the viscous and inertial
forces. If the viscous forces dominate (Re < 2,000), the flow is laminar,
and if the inertial forces dominate (Re > 3,000), the flow is turbulent.
At Re 2,000 to 3,000, the flow is said to be transitional.
The major significance of changes in the flow regime between tur-
bulent and laminar flow is that, for turbulent flow, the pressure loss is
proportional to the square of velocity and in laminar flow the losses are
linearly proportional to the velocity. This means that, for equivalent flow
14 • The Concise Valve Handbook
rates, the differential pressure across the valve will be different for each
flow regime. As stated earlier, the predictions used in sizing calculations
are based on a fully developed turbulent flow in which inertial forces dom-
inate. If, due to a change in viscosity, the flow regime changes, then the
predicted calculations are no longer valid. As a result, a correction factor
can be applied where:
where:
CVR = required CV;
FV = Reynolds number factor; and
CV = valve flow coefficient.
Flashing and cavitation are two related physical phenomena and are the
most common causes of control valve failure. Flashing and cavitation
cause structural damage to the valve and adjacent piping, and in order
to reduce or compensate for these undesirable effects, it is important to
understand the changes that occur to the medium as it passes through
the valve.
Flashing and cavitation only occur within liquids and takes place
whenever the internal pressure of the liquid falls below the vapor pres-
sure. This is illustrated in Figure 1.11 that shows a pressure gradient curve
through a valve where PV represents the vapor pressure of the flowing
P1
Pressure
Vapour pressure PV
P2
PVC
Distance
1.11 Flashing
If, as shown in Figure 1.11, the outlet pressure (P2) of the valve is at or
below the vapor (PV), the vapor bubbles remain intact and proceed fur-
ther downstream. This is known as flashing. The vaporization of liquid
causes a large increase in volume, and therefore higher overall fluid
velocity.
Liquid droplets suspended in a high-velocity vapor flow stream
impinging on metallic surfaces can cause physical damage to carbon
steel and cast iron. The damage is smooth and polished, similar to erosion
(Figure 1.12).
The majority of flashing damage occurs at the point of highest veloc-
ity—at or near the seat line of the valve plug or seat ring. The process is
two-stepped: a corrosion film forms at the surface that is subsequently
‘swept’ away by the high-velocity liquid flow. This cycle is then repeated.
The noise associated with flashing is a high-pitched hissing sound,
similar to that of sand passing through the valve.
1.12 Cavitation
If, further downstream, the outlet pressure (P3) of the valve recovers to a
point above the vapor pressure of the fluid, the vapor bubbles will collapse
(Figure 1.13). This two-stage phenomenon, vapor bubble formation and
their subsequent collapse, is known as cavitation.
Implosion of the vapor bubbles produces large pressure shocks due to
microjet or spherical shock waves. If the vapor bubbles are close to or in
contact with a solid wall, pressure shocks of the order of 100,000 bar (1.5
million psi) are generated, producing both noise and physical damage. If
the bubbles collapse on or near solid surfaces, material is chipped away
(Figure 1.14). The amount of damage in a short period of time can be
P1
P2
Pressure
Vapour pressure PV
PVC
Distance
Figure 1.13. Cavitation is caused by the pressure
dropping to the vapor pressure of the fluid and
rising to a higher pressure further downstream.
extensive and eventually prevents the control valve from performing its
intended function.
Because cavitation damage occurs where the bubbles collapse, the
effects will be evident downstream of the restriction and will show up
as very dull, rough, and pitted—sponge-like in appearance (Figure 1.15).
Corrosion, often mistaken as cavitation, takes on a similar appearance
with its affected area being more generalized or widespread.
The noise associated with cavitation is a high-pitched hissing
sound—usually accompanied by vibration—similar to that of gravel pass-
ing through the valve. The noise levels produced are rarely a problem to
the surrounding environment, but can be used as a good indication of the
severity of the cavitation (Figure 1.16).
Should cavitation be allowed to continue, the next manifestation
will be a loss of seat tightness as the damage starts to affect the seating
surfaces. Further use will cause the normal controlling position to pro-
gressively reduce, as the valve has to move toward the closed position to
compensate for the wear taking place.
As devastating as cavitation damage is, it is fortunate that its occur-
rence is associated with few process fluids. Hydrocarbon mixtures, such
as gasoline, do not have a fixed vapor pressure and will ‘boil’ over a rel-
atively wide temperature range. Gasoline boils from 40°C to 200°C. It is
felt that this results in an apparent buffeting effect, protecting the body
wall and other vital valve components. On the other hand, high surface
tension associated with water enhances the damage potential due to the
high related implosion stresses. In addition to collapse in the vicinity of
surfaces, the potential for damage is high when flowing fluid:
110
100
90
SPL dBA
80
70 Full cavitation
50
0.02 0.04 0.06 0.1 0.2 0.3 0.4 0.6 0.8 1.0
ΔP
P1 − P 2
1.13 Leakage Classification
∆P
Q = 0.87 C v (1.25)
SG f
Basic Principles • 19
3.5
Q = 0.87.50 = 81m3 /hr (1.26)
1
The question now is, how long would it take for a valve meeting
ANSI requirements to fill a 10- litre (about 2.6 gallons) bucket?
Let us look at ANSI II, that is, 0.5% of rated capacity:
0.5% of 81 m3/hr = 0.405 m3/hr
= 405 l/hr
= 6.75 l/min
So, time taken to fill a 10 l bucket would be 1.5 minutes. Not very
good, is it?
What about ANSI III, that is, 0.1% of rated capacity?
0.1% of 81 m3/hr = 0.081 m3/hr
= 81 l/hr
= 1.35 l/min
Basic Principles • 21
So, the time taken to fill a 10 l bucket would be nearly 7.5 minutes.
Still not very good.
And, ANSI IV, that is, 0.01% of rated capacity?
0.01% of 81 m3/hr = 0.0081 m3/hr
= 8.1 l/hr
= 0.135 l/min
Here, the time taken to fill a 10 l bucket would be just over 74 minutes.
And finally, ANSI V, that is, 5 × 10-9 l/s of water per mm orifice per
bar differential
5 × 10-9 × 50 × 3.5 × 60 × 1000 ml/min = 0.0525 ml/min = 132 days
4.5 hours
It should be noted that the foregoing ANSI seat leakage classes apply only
to control valves and not to isolation valves. An isolation valve is designed
solely for that purpose: to stop the flow of a gas or liquid. Consequently,
it is intended for use only in the fully open or closed positions, either to
divert the process media or to isolate it.
While control valves would generally be actuator-operated, isolation
valves can be actuator- or manually operated.
Obviously, the standards for seat leakage rates for isolation valves are
more rigorous than for control valves and are generally governed by API 598.
This states that, for all resilient-seated valves, there shall be no leak-
age at all during the specified test duration, with the period ranging from
15 to 120 s, dependent on the size of the valve. For liquids, 0 drops means
no visible leakage, while for gas, 0 bubbles means less than one bubble
during the test (Table 1.5).
A C
Acoustic insulation, 119 Cage-guided control valve, 55,
Actual pressure drop, 27 58–59
Aerodynamic noise, 117 Camflex eccentric rotary plug
Air-operated pinch valve, 71, 72 valve, 86
Angle valve, 60 Cavitation
damage, 16–17
B elimination, 112–113
Ball segment valve, 81–82 flashing damage, 109
Ball valve liquid noise characteristics,
end-entry design, 76 17, 18
floating ball valve, 75 pressure dropping, 16
‘run’ torque, 76–77 reducing, 110–112
split-body design, 75, 76 Stellite region, 109
top-entry design, 76 trim selection guide, 109
trunnion (see Trunnion ball Center-disc butterfly valve, 82, 83
valve) Check valve, 88, 89
Bar stock body valve, 61, 62 Choked flow, 8–9
Bellows seal bonnet Choked pressure drop, 27
accordion-like tube, 52 Compressibility factor, 43
formed-type bellows, 53 Control valve
leakage detection, 54 basic theory, 3
lifespan, 54 Bernoulli’s equation, 5–8
welded bellows, 53 cavitation, 16–18
Bernoulli’s equation, 5–8 choked flow, 8–9
Bonnet assembly, 49 equation of continuity, 3–4
Butterfly valve final control element, 1–3
center-disc butterfly valve, 82, 83 flashing and cavitation, 14–15
circular disc-shaped damper, 82, fluid properties, 1
83 isolation valve leakage
conventional disc shape, 84, 85 classification, 21
fishtail disc, 84, 85 leakage classification, 18–21
flow characteristics, 84, 85 pressure recovery, 9–11
offset disc, 84 purpose of, 1
136 • Index
linear, 103 M
modified percentage, 105 Manipulated variable (MV), 2–3
plug outlines, 105, 106 Mechanical noise, 115–116
quick opening, 104 Modified percentage inherent flow
Installed flow characteristics characteristics, 105
differential pressure drop, 105, Molecular weight of gas, 41, 42
106 Mufflers, 120
equal percentage, 108
linear, 107 N
pressure drop ratio, 107 Needle valve, 61
valve selection guide, 108 Noise
Isolation valve leakage acoustic insulation, 119
classification, 21 aerodynamic noise, 117
control, 117–118
K hydrodynamic noise, 116
Knife edge gate valve mechanical noise, 115–116
advantages, 67 path treatment, 118–119
disc alignment, 68, 70 permissible personnel noise level
flow/travel characteristics, 68, 69 exposure, 114
sliding gate regulator valve, 68, prediction, 117
70, 71 silencers, 120
V-insert gate valve, 68, 69 sounds and activities, 113, 114
source treatment, 120–122
L Nominal bore (NB), 88–90
Laminar ‘parabolic’ velocity Nominal pipe size (NPS), 88–90
profile, 12
Laminated graphite packing O
benefits, 51 Offset disc butterfly valve, 84
double graphite packing
arrangement, 51 P
electrochemical reaction, 51, 52 Packing box, 49, 50
sacrificial zinc washers, 51 Pinch check valve, 88, 89
temperature, 50 Pinch valve
Lap joint flange, 98–99 air-operated pinch valve, 71, 72
Linear inherent flow applications, 71
characteristics, 103 double vise mechanism, 71, 72
Liquid valve sizing rubber hose/sleeve, 69, 71
Emerson Fisher easy-e®, 27–29 turbulence, 70
identical inlet and outlet fittings, Piping geometry factor, 29–31
31–32 Plug valve
oversized valves, 23 conventional, 84–85
PC-based software package, lubricated valve, 85
23–24 PTFE-lined valve, 86
piping geometry factor, 29–31 sealing mechanism, 85
valve sizing programs, 24 Pressure drop mechanism
138 • Index