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Where:
If the valve has fittings connected directly upstream and/or downstream, the pressure drop ratio factor must be modified to account for expansion and contraction of the fluid through the fittings. The modified pressure drop ratio factor, X TP is calculated using:
Where:
For valves installed with a reducer installed upstream, the inlet fittings head loss coefficient becomes:
Expansion Factor, Y
The expansion factor accounts for the expansion of gas flowing through the valve as the pressure reduces from inlet to outlet. The expansion factor is the ratio of flow coefficients for a gas to that for a liquid at the same Reynolds number. The expansion factor must be less than or equal to a value of 0.667. The following equation defines the expansion factor:
connected directly upstream and/or downstream of the valve. If no fittings are connected to the valve, the piping geometry factor is 1. The piping geometry factor is often listed in valve manufacturers catalogues. Alternatively, it can be calculated using:
Most commonly, the fittings connected to a control valve are upstream and downstream reducers. In this case the sum of the fittings factors for the reducers is:
Note: Determining the control valve Cv becomes an iterative process when the piping geometry factor doesnt equal 1. 1. Estimate the required Cv 2. Select an appropriate valve from the manufacturers tables 3. Calculate Fp and X TP using the actual Cv of the selected valve 4. Re-calculate the required Cv using the values of Fp and X TP determined in Step 3 5. Check that the re-calculated Cv is less than the actual Cv of the selected valve 6. If the re-calculated Cv is less than the actual Cv, the selected valve is adequately sized 7. If the re-calculated Cv is greater than the actual Cv of the selected valve, select another valve with a larger Cv and return to Step 3
1.1 x maximum required flow rate 2. Set the control pressure drop to equal 50% 60% of the frictional pressure loss of the piping system 3. Limit the maximum flow rate : minimum flow rate turndown to 5:1 for linear trim valves and 10:1 for equal percentage trim valves 4. The valve should be able to control the required range of flow rates between 10% and 80% of valve opening 5. Ideally select a valve that has a body size 1 pipe size smaller than the pipe in which it is to be installed (e.g. select a 3 valve for a 4 pipe) 6. Never select a valve larger than the pipe in which it is to be installed
Calculation
Following the steps given at the start of this article: 1. Design flow rate = 56689 kg/hr 2. Allowable pressure drop across the valve = 17.24 bar 3. We will choose an Emerson 4 ED globe valve with linear cage as the preliminary selection. From the valve table we can see that the actual Cv is 236 and X TP is 0.688
4. We will assume that 6 x 4 reducers will be used to install the selected 4 valve in the 6 pipe. In this case the piping geometry factor is: K = 1.5 (1 (4 / 6 )) = 0.463FP = [1 + (0.463 / 890)(236 / 4 ) ] The pressure drop ratio factor, X T = 0.688 The inlet fittings head loss coefficient is: Ki = 0.5 (1 (4 / 6 )) + 1 (4 / 6) = 0.957 So the modified pressure drop ratio factor is: X TP = 0.688 / 0.95 [1 + 0.688 x 0.957 / 1000 (236 / 4 ) ] = 0.667 5. Check if flow through the valve is sub-critical or critical: Fk = 1.28 / 1.4 = 0.91Fk X TP = 0.91 x 0.667 = 0.607(P1 P2 ) / P1 = (35.50 18.26) / 35.50 = 0.486 Therefore: (P1 P2 ) / P1 < Fk X TP so the flow is sub-critical 6. The effective pressure drop ratio across the valve is (P1 P2 ) / P1 because the flow is subcritical: X eff = 0.486 7. Calculate the expansion factor: Y = 1 0.486 / (3 x 0.91 x 0.667) = 0.733 8. Calculate the first estimate of Cv: Cv = 56689 / (27.3 x 0.95 x 0.733 (0.486 x 35.50 x 16.71) ) = 175.6 9. The calculated required Cv of 175.6 is less than the actual Cv of the selected valve of 236 so the valve is large enough 10. Check if the control valve range is OK: From the valve table, the selected valve will be a just less 70% open to give the required Cv of 175.6. This is within the acceptable control range of 10% to 80% of valve opening. 11. The selected 4 linear cage valve is correctly sized for the specified duty
0.5 2 2 2 -1 2 2 2 4 2 2 2 2 2 -0.5
= 0.95
Result
The selected valve is an Emerson 4 ED globe valve with linear trim and a maximum Cv of 236.
The selected valve is an Emerson 4 ED globe valve with linear trim and a maximum Cv of 236.
How To
There are other important factors to consider when selecting a control valve, such as valve type and valve characteristic but this article will concentrate on valve sizing. Sizing a control valve for a particular duty is governed by the required flow rate the valve must pass and the pressure drop that can be allowed across the valve.
However, the procedure is fairly simple and straightforward. It becomes even easier if it is known that the liquid will not flash or cavitate as it flows through the valve. For preliminary estimates of control valve size it is usually OK to assume that the piping geometry factor is 1.
Where:
If no fittings are connected to the valve, the piping geometry factor is 1. The piping geometry factor is often listed in valve manufacturers catalogues. Alternatively, it can be calculated using:
Most commonly, the fittings connected to a control valve are upstream and downstream reducers. In this case the sum of the fittings factors for the reducers is:
Note: Determining the control valve Cv becomes an iterative process when the piping geometry factor doesnt equal 1. 1. Estimate the required Cv 2. Select an appropriate valve from the manufacturers tables 3. Calculate Fp using the actual Cv of the selected valve 4. Re-calculate the required Cv using the value of Fp determined in Step 3 5. Check that the re-calculated Cv is less than the actual Cv of the selected valve 6. If the re-calculated Cv is less than the actual Cv, the selected valve is adequately sized 7. If the re-calculated Cv is greater than the actual Cv of the selected valve, select another valve with a larger Cv and return to Step 3
1.1 x maximum required flow rate 2. Set the control pressure drop to equal 50% 60% of the frictional pressure loss of the piping system 3. Limit the maximum flow rate : minimum flow rate turndown to 5:1 for linear trim valves and 10:1 for equal percentage trim valves 4. The valve should be able to control the required range of flow rates between 10% and 80% of valve opening 5. Ideally select a valve that has a body size 1 pipe size smaller than the pipe in which it is to be installed (e.g. select a 3 valve for a 4 pipe) 6. Never select a valve larger than the pipe in which it is to be installed
Calculation
Following the steps given at the start of this article: 1. Design flow rate = 800 US gpm 2. Allowable pressure drop across the valve = 25 psi 3. We will choose an Emerson 3 ES globe valve with linear trim as the preliminary selection. From the valve table we can see that the actual Cv is 135 and FL is 0.89
4. We will assume that 4 x 3 reducers will be used to install the selected 3 valve in the 4 pipe. In this case the piping geometry factor is: K = 1.5 (1 (3 / 4 )) = 0.287 FP = [1 + (0.287 / 890)(135 / 3 ) ]
2 2 -0.5 2 2 2
= 0.96
5. Check if flow through the valve is sub-critical or critical: FF = 0.96 0.28 (124.3 / 616.3) = 0.83 DPmax = (0.89) (314.7 0.83 x 124.3) = 167.6 psi P1 P2 = 314.7 289.7 = 25 psi Therefore: P1 P2 < DPmax so the flow is sub-critical 6. The effective pressure drop across the valve is P1 P2 because the flow is sub-critical DPeff =25 psi 7. Calculate the first estimate of Cv: Cv = (800 / 0.96)(0.5 / 25)
0.5 2
= 117.9
8. The calculated required Cv of 117.9 is less than the actual Cv of the selected valve of 135 so the valve is large enough 9. Check if the control valve range is OK: From the valve table, the selected valve will be about 75% open to give the required Cv of 117.9. This is within the acceptable control range of 10% to 80% of valve opening. 10. The selected 3 linear trim valve is correctly sized for the specified duty
Result
The selected valve is an Emerson 3 ES globe valve with linear trim and a maximum Cv of 135.
How To
Flow Rate
Usually, the flow rate of liquid a pump needs to deliver is determined by the process in which the pump is installed. This ultimately is defined by the mass and energy balance of the process. For instance the required flow rate of a pump feeding oil into a refinery distillation column will be determined by how much product the column is required to produce. Another example is the flow rate of a cooling water pump circulating water through a heat exchanger is defined by the amount of heat transfer required.
The discharge pipe outlet may be above the surface of the liquid in the discharge vessel or it may be submerged as shown in these 3 diagrams.
Pump Suction
In order to calculate the frictional head losses you therefore need to know the lengths and diameters of the piping in the system and the number and type of fittings such as bends, valves and other equipment.
Pump Power
Pumps are usually driven by electric motors, diesel engines or steam turbines. Determining the power required is essential to sizing the pump driver. Pump pow er = flow rate x total differential head x liquid density x ac c eleration due to gravity pump effic ienc y
Calculation
The calculation is presented below:
Results
Pump flow rate = 30 m /hr Pump total differential head = 134.8 m Net positive suction head available = 22.13 m Pump power = 15.7 kW
3
Technical Information
13. Are pipes considered to be piping under the PED when they are placed on the market as individual components? 14. Can you give some examples of pressure assemblies? 15. Is on site assembly of pressure equipment by the user covered by the PED? 16. How is the PED enforced in the UK, compared with national legislations in other EU countries? Does the PED apply to vessels under vac uum? Equipment with maximum allowable working pressures of less than 0.5 barg are exempt from the Pressure Equipment Directive. Such equipment should be designed, built and tested to appropriate standards but this equipment is not covered by the PED.
Rating: +3
How is a valve c lassified under the PED? Valves are usually classified as pressure accessories. However, the PED
Rating: +3
category of a valve is usually determined based on the valve nominal diameter in which case the classification charts for piping can be used. If the valve has a significant internal volume, the classification should be carried out using the classification charts for both piping and vessels and the higher category selected.
How is a heat exc hanger c lassified under the PED? Heat exchangers are generally considered to be pressure vessels. However, the following type of heat exchanger is treated as piping:
Rating: +1
Heat exchangers consisting of straight or bent pipes which may be connected to common circular headers also made of pipe providing that air is the secondary fluid, they are used in refrigeration systems, in air conditioning systems or in heat pumps and that the piping aspects are predominant. For more details see Guideline 2/4
How should a vessel that c ontains both a liquid and a gas be c lassified?
Rating: +0
The vessel should be classified on the basis of the fluid which requires the higher category. The total volume of the vessel should be used to determine the category not the actual volumes occupied by the individual fluids.
Can the ASME Boiler and Pressure V essel Code Sec tion V III be used to design pressure vessel to c omply w ith the PED?
Rating: +1
National standards and professional codes (including ASME VIII) can be used for the design and manufacture of pressure equipment. However, a notified body may be required to validate the selected approach if the equipment is categorised as Category II, III or IV. See Guideline 9/5
W here c an I find a list of notified bodies? A list of all EU approved notified bodies is given here: Notified Bodies
Rating: +1
How do I c lassify a pressure ac c essory ? A pressure accessory should be classified based on its characteristic
Rating: +2
How do I c lassify a pressure ac c essory ? A pressure accessory should be classified based on its characteristic
Rating: +2
dimension diameter or volume. If both diameter and volume are relevant, the equipment should be classified according to whichever gives the higher category. For example, a valve is usually classified using diameter as the characteristic dimension whereas a filter is usually classified using volume as the characteristic dimension.
Is PED c lassific ation required if w e already have ISO, API or ASME c ertific ation? PED classification is required in addition to other certification.
Rating: +0
W hen is equipment required to c arry CE marking? The PED requires equipment that is classified as Category I, Category II,
Rating: +0
Category III and Category IV to carry CE marking. Equipment classified as SEP must not carry CE marking.
Are all dangerous fluids c lassified as Group 1 fluids? No. Only fluids classified as: Explosive Extremely flammable Highly flammable Very toxic Toxic Oxidising
Rating: +0
How should a mixture of fluids be c lassified? If a mixture of fluids contains at least one Group 1 fluid, the mixture
Rating: +2
should be classified as a Group 1 fluid. The exception to this is if the safety datasheet for the mixture allows it to be classified as a Group 2 fluid.
Are replac ements, repairs or modific ations to pressure equipment c overed by the PED?
Rating: +2
Complete replacement of an item of pressure equipment by a new one is covered by the PED. Repairs are not covered by the PED but may be covered by national regulations. Pressure equipment that has been modified to change its original characteristics, purpose and/or type after it has been put into service is covered by the PED.
Are pipes c onsidered to be piping under the PED w hen they are plac ed on the market as individual c omponents?
Rating: +2
Individual piping components such as pipes, tubing, fittings, expansion bellows or other pressure bearing components are not considered to be piping under the PED until they are assembled into a system. However, a single pipe or system of pipes for a specific application can
Individual piping components such as pipes, tubing, fittings, expansion bellows or other pressure bearing components are not considered to be piping under the PED until they are assembled into a system. However, a single pipe or system of pipes for a specific application can be classed as piping under the PED if all appropriate manufacturing operations such as bending, forming, flanging and heat treatment have been completed. On this basis, PED classification of general piping stock would not be carried out by the piping supplier. The pipes and components would be classified by the organisation responsible for the manufacture of the piping system.
Can y ou give some examples of pressure assemblies? Examples of pressure assemblies given in the PED guidelines include
Rating: +1
pressure cookers, portable extinguishers, breathing apparatus, skid mounted systems, autoclaves; air conditioner, compressed air supply in a factory, refrigerating system, shell boilers, water tube boilers, distillation, evaporation or filtering units in process plants, oil heating furnaces.
Rating: +0
Pressure equipment assembled on site under the responsibility of the user is not covered by the PED. Usually the separate components of the system being assembled by the user such as pressure vessels, valves, piping systems are covered by the PED. The completion of pressure assemblies on site by the manufacturer is covered by the PED.
How is the PED enforc ed in the UK, c ompared w ith national legislations in other EU c ountries?
Rating: +1
The PED is enforced in the UK by the Pressure Equipment Regulations 1999. These regulations make compliance with the Pressure Equipment Directive a legal requirement in the UK. Failure to comply with these regulations can result in prosecution and penalties on conviction of a fine, imprisonment or both. Similar legislation has been enacted in all member states of the European Economic Area. The central purpose of the PED is to harmonise the national laws of the member states regarding the design, manufacture, testing and conformity assessment of pressure equipment and to remove technical barriers to trade. Therefore, compliance with the PED under any member state's legislation entitles a manufacturer to sell pressure equipment throughout the European Economic Area.
Question:
Technical Information
Air-Cooled Exchangers
Hot fluid Water Light or ganics Heavy or ganics Gases (5 - 10 bar ) Gases (10 - 30 bar ) Condensing hydr ocar bons Cold fluid Air Air Air Air Air Air Overall HTC (W /(m2.K)) 300 - 450 300 - 700 50 - 150 50 - 100 100 - 300 300 - 600 Overall HTC (Btu/(hr.ft2.F)) 53 - 79 53 - 123 9 - 26 9 - 18 18 - 53 53 - 106
Air Air
18 - 53 53 - 106
Jacketed Vessels
Jacket Steam Steam Water Water Vessel Dilute aqueous solutions Light or ganics Dilute aqueous solutions Light or ganics Overall HTC (W /(m2.K)) 500 - 700 250 - 500 200 - 500 200 - 300 Overall HTC (Btu/(hr.ft2.F)) 88 - 123 44 - 88 35 - 88 35 - 53
Light or ganic V iscous or ganic Light or ganic V iscous or ganic Condensing steam Condensing steam Pr ocess water Pr ocess water Dilute aqueous solutions Condensing steam
Pr ocess water Pr ocess water Cooling water Cooling water Light or ganic V iscous or ganic Pr ocess water Cooling water Cooling water Pr ocess water
2500 - 3500 250 - 500 2000 - 4500 250 - 450 2500 - 3500 250 - 500 5000 - 7500 5000 - 7000 5000 - 7000 3500 - 4500
440 - 616 44 - 88 352 - 792 44 - 79 440 - 616 44 - 88 880 - 1321 880 - 1233 880 - 1233 616 - 792
Blackmonk News
Technical Information
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Over the last couple of years Ive worked on a number of projects that have involved the European Union Pressure Equipment Directive (or PED as its sometime known). The Directive is legislation which aims to ensure that pressure equipment used within the EU is safe. For the process industries, this most often means vessels and piping. A key part of complying with the PED is to ensure that equipment has been classified correctly. Basically this classification categorises equipment according to the degree of hazard should the equipment fail. Equipment in the most hazardous applications, for instance large vessels containing toxic or flammable gases at high pressure, is required to have extensive quality assurance procedures throughout the design, manufacture and testing stages. Equipment in low hazard applications, such as a small storage vessel for water at low pressure, has less onerous quality assurance requirements. In the projects Ive been involved with, equipment classification has been the responsibilty of the process engineers although the information is required by the other disciplines, especially piping and control/instrumentation engineers. Higher classification requirements also tend to affect equipment cost and delivery, so project managers also have a keen interest! Given that the PED is a legal requirement, along with potential cost and delivery implications, it is essential that equipment classification is carried out thoroughly and accurately. To help you classify equipment correctly, I have written a free guide to the Pressure Equipment Directive which is available to download to all Blackmonk email subscribers. To get your free copy just enter your name and email details into the boxes above or on the right hand side of this page. I hope you find the guide useful and would appreciate any comments you might have. Regards, Simon.
I hope you find the guide useful and would appreciate any comments you might have. Regards, Simon.
Blackmonk News
Blackmonk News
Updated Website
July 31, 2009 No comments yet Weve been updating our website over the past couple of weeks to make it more user friendly. We hope you like it. Comments can now be left directly via the site on various pages and the navigation has been improved. The free calculators are still there and now they should be easier to find! In addition weve added a blog where well be writing articles relevant to those of us in the process industries. As always, we would appreciate your feedback on the new website. Best regards, Simon.
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