Workshop Notes

Modulating 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 Date : 22/01/2014
Version : V2.0.1 Date : 06/01/2014 Sheet 1 of 3
Customer Tag # FCV 01
Project UK #2 Sizing Item # #1-[2] FCV 01 Example
Enquiry Ref. Application Bray School
Quotation # Function Control
1 Process Fluid Liquid / Water Phase Single Critical Press. Pc 3193.3929 psig
Units Min Norm 1 Norm 2 Max Shut-Off

2 Design Press. (Max.) psig 150

3 Design Temp. (Min. / Max.) °F 33 / 100
4 Flow Rate (Liquid) gpm (US) 500 1000 1500 3500
5 Inlet Pressure psig 20 16 14 12 150
6 Outlet Pressure psig 6 7 8 10
7 Inlet Temperature °F 70 70 70 70
8 Sp. Gravity 0.998 0.998 0.998 0.998
9 Viscosity cP (CentiPoise) 0.976 0.976 0.976 0.976
10 Vapour Pressure psig -14.33 -14.33 -14.33 -14.33
11 Calculated Cv 133 333 618 3037
12 Travel Deg 21.6 34.8 46.4 77.4
13 Pressure Drop psid 14 9 6 2
14 Choke Drop psid 22.446 21.406 19.188 15.339
15 Noise (Allow / Predict) dBA < 70 < 70 < 70 < 70
16 Outlet Velocity ft/s 2.034 4.069 6.103 14.24
17 Velocity Warning
18 Flow Warning Cavitation
19 In Pipe Size / Sch. 10 in / STD Actuator Type Pneumatic - Spring Return (Rack & Pinion) 44
20 Out Pipe Size / Sch. 10 in / STD Mfr. / Model Bray / Series - 93 45
21 Valve Type Resilient Size / No. of Spring 160 / 5 46
22 Size / Rating Standard 8" / ASME Max. Allow. Pressure 120 psig 47
23 Rating CL 125/150 Min. Req. Pressure 40 psig 48
24 Pressure Rating Full Pressure rating Min. Avl. Air Pressure 80 psig 49
25 Valve Series Series 21 Max. Avl. Air Pressure 120 psig 50
26 Body Material St. Steel, ASTM A 351 Gr CF8M Fail Action Close 51
27 Extension Bonnet N/A Act. Orientation Perpendicular 52
28 End Connection Lug Manual Override No 53
29 Flg. Face Type / Finish N/A Pos. Mfr. / Model Bray-Series 6A 54
30 Flow Direction Bi - directional Pos. Type Electro Pneumatic 55
31 Body Bolting B8 / Gr 8 Input Signal 4 - 20 mA 56
32 Disc SS 316 Gauges Yes 57
33 Stem SS 316 Signal Action Direct 58
34 Stem Packing N/A Certification None 59
35 Seat Type Soft Air. Mfr. / Model / Range Bray-Series 55 / 0 – 125 psig 60
36 Seat Material Teflon/EPDM (Standard) Pos. Indi. Mfr. / Model None 61
37 Body Seal N/A L. Sw. Type / Contacts Proximity (Non-Contacting) / SPDT 62
38 Liner N/A L. Sw. Rating / Pos'n IS / Open 63
39 Rated Cv 5191 Solenoid Type / Vol. None 64
40 Flow Characteristics Equal Percentage Air Lock Valve None 65
41 Fire Safe Valve N/A Volume Tank Bray 66
42 NACE Compliance No Volume Booster Bray 67
43 Leakage Class Bubble Tight Shut Off 68
Notes Revisions
1 Demo Valve for Control Vave Sizing Work Shop Rev. By Date
2 Export Crating 0 Roger Barnes 21.01.14
3 Basic Outline Drawing 1 Roger Barnes 22.01.14
4 Hold Point to Witness Test/Inspection 2 Roger Barnes 22.01.14
5 Standard Factory Tests
6 Visual / Dimensional Report
7
8
9
10
11
12
13
 VALVE SIZING CALCULATION SHEET Date : 22/01/2014
Version : V2.0.1 Date : 06/01/2014 Sheet 2 of 3
Customer Tag # FCV 01
Project UK #2 Sizing Item # #1-[2] FCV 01 Example
Enquiry Ref. Application Bray School
Quotation # Function Control
Item Description Series 21, 8", CL 125/150, Lug
SERVICE AND SIZING Min Norm 1 Norm 2 Max
Process Fluid Name Water
Inlet Pressure (psig) 20 16 14 12
Outlet Pressure (psig) 6 7 8 10
Liquid Flow (gpm (US)) 500 1000 1500 3500
Vapour Pressure (psig) -14.33 -14.33 -14.33 -14.33
Specific Gravity 0.998 0.998 0.998 0.998
Temperature (°F) 70 70 70 70
Pressure Recovery Factor, FL 0.808 0.837 0.815 0.647
Valve Style Modifier Factor, Fd 0.356 0.414 0.466 0.542
Combined Recovery Factor, FLP 0.808 0.837 0.815 0.647
Piping Correction Factor, Fp 0.999 0.997 0.989 0.81
Critical Pressure Ratio Factor, Ff 0.957 0.957 0.957 0.957

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

Inlet Pipe Diameter , D1 (in) 10.75 10.75 10.75 10.75
Outlet Pipe Diameter, D2 (in) 10.75 10.75 10.75 10.75
Cavitation Index, Kc 0.408 0.297 0.212 0.076

Sizing Coefficient, Cv 133 333 618 3037

Pressure Drop (psid) 14 9 6 2
dP Choked (psid) 22.4459 21.4058 19.1881 15.3389

Noise Calculation
Valve Type Butterfly Butterfly Butterfly Butterfly
Downstream Pipe Size (in) 10 10 10 10
Downstream Pipe Schedule STD STD STD STD
Valve SPL (dBA) < 70 < 70 < 70 < 70

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

Valve Series : Series 21 Degree Opening,

Calculated Cv
Valve Size: 8"
A - (21.6,133)
Rated Cv: 5191
B - (34.8,333)
Flow Char: Equal Percentage
C - (46.4,618)

D - (77.4,3037)

Travel Deg 9 18 27 36 45 54 63 72 81 90
Cv 11.7 87.4 202.6 353.8 570.5 887.2 1383.4 2228.4 3580.9 5191
 ACTUATOR SIZING SHEET Date : 22/01/2014
Version : V2.0.1 Date : 06/01/2014 Sheet 3 of 3

Customer Tag # FCV 01

Project UK #2 Sizing Item # #1-[2] FCV 01 Example
Enquiry Ref. Application Bray School
Quotation # Function Control
Item Description Series 21, 8", CL 125/150, Lug, Pneumatic - Spring Return (Rack & Pinion), Series - 93

ACTUATOR SIZING

Valve Model Series 21

Valve Size (in) 8
Media Water
Temperature (°F) 100
Maximum Inlet Pressure (psig) 20
Maximum Pressure Drop (psid) 14
Shut off Pressure (psig) 150
MAST (lbs-in) N/A
Basic Torque (lbs-in) 1825
Safety Factor 1.2
Torque with Safety factor 2190
Min. Available Air Supply Pressure (psig) 80
Max. Available Supply Pressure (psig) 120
Actuator Type Pneumatic - Spring Return (Rack & Pinion)
Fail Safe Condition Fail Close
Manual Override No
Actuator Model & Size Series - 93 & 160
No of Spring 5
Spring Start Torque (lbs-in) 3917 lbs-in
Spring End Torque (lbs-in) 2240 lbs-in
Pneumatic Start Torque (lbs-in) 3502 lbs-in
Pneumatic End Torque (lbs-in) 1825 lbs-in

3502 lbs-in 3917 lbs-in

1825 lbs-in 2240 lbs-in

Notes:

R
CONTROLS
Workshop Notes
1-22-2014