Masoneilan Control Valve Sizing

This is the orignal Dresser Masoneilan Control Valve Handbook OZ1000.

This control valve handbook on control valve sizing is based on the use of
nomenclature and sizing equations from ISA Standard S75.01 and IEC Standard
534-2. Additional explanations and supportive information are provided beyond the
content of the standards.

The sizing equations are based on equations for predicting the flow of compressible
and incompressible fluids through control valves. The equations are not intended for
use when dense slurries, dry solids or non-Newtonian liquids are encountered.

Original equations and methods developed by Dresser Masoneilan are included for
two-phase flow, multistage flow, and supercritical fluids. Values of numerical factors
are included for commonly encountered systems of units. These are United States
customary units and metric units for both kilopascal and bar usage.

The principal use of the equations is to aid in the selection of an appropriate valve
size for a specific application. In this procedure, the numbers in the equations consist
of values for the fluid and flow conditions and known values for the selected valve at
rated opening. With these factors in the equation, the unknown (or product of the
unknowns, e.g., Fp Cv) can be computed.

Although these computed numbers are often suitable for selecting a valve from a
series of discrete sizes, they do not represent a true operating condition. Some of
the factors are for the valve at rated travel, while others relating to the operating
conditions are for the partially open valve. Once a valve size has been selected, the
remaining unknowns, such as Fp, can be computed and a judgement can be made
as to whether the valve size is adequate. It is not usually necessary to carry the
calculations further to predict the exact opening.

To do this, all the pertinent sizing factors must be known at fractional valve openings.
A computer sizing program having this information in a database can perform this
task.

A comprehensive set of Cv factor tables for all Dresser Masoneilan valves is

included in one handy reference. This tabulation supersedes all previous listings
since many changes were requiered to bring all ratings in line with actual test data
taking into account the use of the critical flow factor, Cf.
 The formulas in the early chapters are set up in sections to simplify manual
calculation for the more common control valve sizing problems.

Why Dresser Masoneilan Valves Are Calculated?

Control valve sizes are calculated for two reasons:

1. To keep the installation expense down by using as small valve as possible.

2. To select a size which is large enough to handle the maximum required capacity, yet
small enough to close down to the minimum required capacity without seating.
While the dollar cost is of great importance to a user, the Instrumentation Engineers,
as automatic control specialists, are primarily interested in valve size from the
engineering point of view as summarized in (2) above.

There are good reasons why “equal percentage characteristic” control valves (i, e.
the 50:1 rangeability) usually recommended by the Instrumentation Engineers are
considered the standard against which to compare the flow characteristics of all
other styles of inner valves.

The equal percentage curve provides a characteristic distorted less by line pressure
losses which rob the valve of pressure drop.

How Dresser Masoneilan Valves are Sized?

A brief outline of the usual way in which control valve sizes are determined will be of
interest to many readers. The numerous details will not be covered here; separate
articles treat the subject thoroughly for those who need specific help in actual valve
sizing.

All calculations do employ the same basic procedures, however, and can be set
forth in an outline of few words.

An almost universal approach to valve sizing today is through the Cv factor method.
The capacity rating, Cv, (sometimes called flow coefficient) is the expression of a
valve’s capability of handling flow as defined in its rate of discharge of water under a
fixed pressure drop condition of 1 psi.

All kinds of flowing fluids at various pressures and temperatures can be reduced by
computation methods to terms of a required Cv factor for a particular installation,
Once this has been done, it is a simple matter to select the appropriate size of
control valve from a list of Cv’s for the style of valve wanted.

There are three basic formulas published in the literature from which a value of Cv
factor can be obtained:
 one equation is used for liquids
 one is for use with gases
 and one is for steam and other vapors
All stem from the velocity head component in Bernoulli’s theorem, that
is, v^2 = 2gh.

The three equations, when used with a thorough understanding of their limitations,
i.e. :

 how the process data must be adjusted for varying temperatures

 densities
, and so forth, provide a means of accurately determining the
Cv requirement for all flowing materials. No nomograph, no special slide rule
or other short cut means can do anything for the valve calculator that these three
equations will not do.

In fact, the three equations will do much that short cut means cannot
accomplish. They must be resorted to from time to time to handle calculations
that cannot be made correctly otherwise.

How does one make use of the computed Cv

factor?
There are two methods commonly employed, either of which is acceptable:

1. The first is to use an estimated maximum flow rate with a carefully estimated (see next
section) pressure drop at this maximum rate. This method produces a maximum
required Cv factor from which the valve size can be selected from a list of Cv‘s. The
premise is that the normal rate to be handled is easily provided for by a partly opened
valve along the lines discussed in the previous section.
2. A second approach calls for a calculation of the required Cv factor for normal flow rates
with carefully estimated pressure drops at these rates. This gives the Cv
factor requirement for the normally operating valve. By increasing this value by a
reasonable percentage factor the maximum Cv factor is established from which the size
is selected.
Characteristic curves of various inner valve styles are often consulted in the second
method. By experience, some engineers feel confident in placing their normal operating
strokes at a certain fraction of full stem travel. They seem satisfied if the listed Cv factor
is something in excess of their maximum Cv as increased from the computed normal.
Such a procedure can tend to produce some oversized valve installations, unless much
care is exercised.

While either procedure is permissible, it must be borne in mind that the maximum Cv
factor calculation method is more direct and invariably leads to a valve size ample for
the process conditions at hand.
The Question of Pressure Drop
The importance of using carefully estimated, realistic values of pressure drop in
valve size computations cannot be overemphasized. One must constantly
remember that pressure drop which is to occur in the control valve plays almost as
prominent a part as flow rate. In contrast with the more readily established estimates
for rates of flow, selection of representative pressure differentials is not always
easily made.

The function of a Dresser Masoneilan valve is to adjust its area to provide the rate of
flow needed for maintaining a set control point. Not only does valve port area depend
on the rate to be handled, but upon the excess pressure in the process system – all
or a portion of which will appear across the valve ports. Just how much excess
pressure occurs depends on process equipment and piping details.

The process designers must necessarily work with many variables and
approximations. If the control valve were not installed, the varying pressures would
be absorbed in other parts of the equipment and the resulting flow would be
excessive, unpredictable and rampant in nature. To remedy such chaotic conditions,
automatic controllers are used and the control valve does the chore.

Is it not logical, then, to study the proposed

operating conditions with the object of selecting
realistic pressure drops from careful engineering
surveys of all factors that can affect the proposed
valve?
Dresser Masoneilan valves utilize the surplus pressures even though the popular
misconception is that valves create the drop. In performing the valving function, the
restrictive ports control the flow rate so that the excess pressures become
centralized in one place – at the ports of the valve.

Many control valve specifications are written which give questionable pressure
drops. There are probably several reasons for including such arbitrary numbers; but
it is obvious that artificial data cannot be used in valve sizing. The seriousness of
computing Cv factor values on the customary “5 psi drop available”is shown in the
following table:
 Cv factor
Table
For example, if the size calculation is made on a 5 psi drop, but the valve
must actually perform with a 20 psi drop, the Cv calculation is high by 100 percent
and an oversized control valve results.

In arriving at a suitable value for pressure drop, there is no substitute for

good engineering judgment, conscientiousness and experience. It is
recognized that, in some valve applications, all the pressure loss in a system will
not show up across the valve ports. In such cases, the engineering judgment
called for in estimating what drops will occur at the valve may require careful
analysis of the system hydraulics.

While such conditions are relatively few, they certainly demand more careful
consideration than a casual specification of “5 psi drop available” as a means of
side-stepping the issue. There are no fixed rules that always apply, but a critical
study of all the process pressure conditions should lead to reasonably representative
values for use in computing Cv.

Definition of Flow Coefficient Cv

The accepted method of valve sizing in the U.S.A. is the Cv factor approach. Cv is a
capacity rating coefficient which is defined as the number of U.S. gpm of 60°F water
which will flow through a valve at a specified opening with a pressure drop of 1 psi
across the valve.
In Europe, the Kv and Av coefficients are more widely used. Economics and control
are the two principal reasons for sizing control valves.

Economics
If a valve is too small, it will not pass the required flow arid will have to be discarded
and replaced by a larger, properly sized valve. Similarly, if the valve is too large, it
will obviously pass the required flow, but it will be more expensive than a properly
sized, smaller valve.

Control
An undersized valve will never deliver the full flow rate, thus it will
sharply narrow the controllable flow range. An oversized valve will be throttling near
the closed position, and the full control range of the valve will not be utilized.

When the plug throttles very close to the seat, high fluid velocities occur which can
cause erosive damage. The ideal valve is one that will function between 40 and 70%
of its operating range, going neither wide open under maximum flow rates, nor
closing down too near its seated position under minimum conditions.

The Dresser Masoneilan Cv factor tables in this post will allow the user to select the
ideal valve for the required application.

General
When the Cv, or capacity of a valve, versus the percent valve stroke from 0 to 100%
is plotted, a curve is generated. The shape of this curve can be varied by varying
the valve capacity or gain at some predetermined rate.

The curve generated is called the valve de sign characteristic.

 Curve Valve Characteristic
Equal Percentage Characteristic
For an equal increment of valve stem position, an equal percent change in valve
capacity will occur.

This means that the same percent increase will occur between a 30 and 40% valve
stem position as between an 80 and 90% valve stem position.
For example, for a nominal valve with a rated Cv factor of 15.0 and having an equal
percentage characteristic, we find the following:
Equal Percentage Characteristic

Only in theory is the gain exactly the same for equal increments of valve stem
position. In practice, the gain can and does vary from the theoretical.

Linear Characteristic
For equal increments of valve stem position, there is a corresponding equal
increment of flow. This means that flow is proportional to valve stem position and
that the same change in valve capacity will occur between a 30 and 40% valve stem
position as belween a 70 and 80% valve stem position.
For example, referring a valve wilt a rated Cv of 34.0, and having a linear
characleristic, we find lhe following:
 Linear
Characteristic
Although in this example the flow increments are identical, in practice, these values
can and do vary from the theoretical.

Control Valve Selection Guide Characteristic

The control valve selection with the proper operating characteristics is one of the
most important phases of designing a control loop, It is not enough to assume that
a wide proportional band plus integral controller will overcome a serious mismatch
between the process and the valve characteristic. An exact match would usually
require a valve custom designed for the process. However, one or the other of two
standard characteristics (linear or equal percentage) is practically always suitable for
any given process. This is important because a serious mismatch might cause the
system to be unstable and difficult to control effectively.

In actual practice, a valve has two characteristics:

1. One is the design or inherent characteristic , determined by laboratory test and defined
as the relationship between flow and stroke with constant pressure drop.
2. The other, the resultant characteristic, is more significant.This is the relationship
between flow and stroke when the valve is subjected to the pressure conditions of the
process.
Cv factor is an expression for liquid flow at a constant pressure drop, The graphic
display of flow versus lift shows how the design or inherent characteristic is changed
by variations in pressure drop.
Differential Pressure Effects
This occurs as the process changes from a condition where most of the pressure
drop takes place at the control valve (usually at low flow rates) to a condition where
most of the pressure drop is generally distributed through the rest of the system
(usually at high flow rates).

This variation in where most of the total drop takes place is one of the most
important aspects in choosing the proper valve characteristic for a given process.

There are two other very important considerations in choosing the proper valve
characteristic. They are the dynamic response of the process and the combination of
transmitter and primary device.

To exactly determine the dynamic response of a process requires a complete

dynamic analysis for each control loop. This is difficult and usually impractical. It is
possible to establish general guidelines based upon the extensive experience in field
startups and troubleshooting.

The following paragraphs are discussions of normal control applications encountered

in industrial instrurmentation. Proper valve characteristic recommendations are
included :
 FLOW RATE CONTROL
One of the two types of flow measurement signals

 linear with differential pressure or

 linear with flow rate
are incorporated in flow rate control. These two types of measurement require
separate treatment since they seriously affect dynamic response.

Case 1

1. Measurement signal: linear with flow rate

2. Maximum to minimum valve pressure drop with varying flow rates: Greater than 2 1/2
to 1
3. Valve pressure drop at maximum flow:Less than 40 percent of system drop including
valve
Recommendation: Equal percentage valve

Case 2

1. Measurement signal: linear with flow rate

2. Maximum to minimum valve pressure drop with varying flow rates: Less than 2 1/2 to
1
3. Valve pressure drop at maximum flow: More than 40 percent of system drop including
valve
Recommendation: Linear valve

Case 3

1. Measurement signal: Linear with differential pressure

2. Maximum to minimum valve pressure drop with varying flow rates: Greater than 5 to 1
3. Valve pressure drop at maximum flow: Less than 20 percent of system drop including
valve
Recommendation: Equal percentage valve

Case 4

1. Measurement signal: Linear with differential pressure

2. Maximum to minimum valve pressure drop with varying flow rates: Less than 5 to 1
3. Valve pressure drop at maximum flow: More than 20 percent of system drop including
valve
Recommendation: Linear valve

PRESSURE CONTROL
Pressure control is subdivided into two classes de pending upon the pressure
conditions of the system. When the control valve is to maintain a constant pressure
drop to satisfy the control requirements, a linear valve should be used. When the
valve is to operate with a varying pressure drop of over 2 to 1 to satisfy the control
requirements of the hydraulic system, an equal percentage valve should be used.

TEMPERATURE CONTROL
In just about every case, temperature control requires an equal percentage valve for
optimum control. Foxboro designed the first equal percentage valve specifically for
temperature control when adequate control could not be maintained by existing
valves. A temperature control system should be such that the ratio of maximum to
minimum valve pressure drop is less than 2 to 1.

LIQUID LEVEL CONTROL

Liquid level control is best satisfied by a valve with an equal percentage
characteristic when the ratio of maximum to minimum valve pressure drop is greater
than 2 1/2 to 1. When this ratio is less than 2 1/2 to 1, a linear valve characteristic
gives better performance.

pH CONTROL
Concentration, as measured by analysis such as pH, is best controlled by a valve
with an equal percentage characteristic When the ratio of maximum to minimum
valve pressure drop at full flow is greater than 2 to 1. When this ratio is less than 2 to
1, a linear valve characteristic gives better performance.

GENERAL RULES OF APPLICATION

For stability over the entire control range, most control loops require flow to be
manipulated in uniform proportion to controller output. Frictional losses through pipes
and fittings increase and pump output pressures decrease with increasing flow.
Therefore, the available pressure drop at the control valve usually diminishes as the
flow rate increases. To maintain the desired uniform proponionality, an equal
percentage characteristic is often required in these varying pressure drop
applications. A linear characteristic is preferable on all but temperature control
applications when a nearly constant pressure drop exists at the control valve.

A misapplied equal percentage valve characteristic results in increasing valve gain at

high flow rates. It can cause instability unless the controller proportional gain is
adjusted at the high flow rate. The control loop then tends to be overdamped at the
low flow rates with correspondingly sluggish response.

A misapplied linear valve exhibits the opposite effect. A controller properly adjusted
at the high flow rate has too narrow a proportional band setting for stability at low
 flows. The proportional gain has to be adjusted at the low flow rates, and the control
loop is then overdamped and sluggish at higher flow rates.

The above recommendations are only as good as the hydraulic analysis of the
pressure conditions in the system. Maximum pressure drop can usually be deter-
mined fairly exactly since it is close to the shutoff pressure. Minimum valve pressure
drop at full flow is occasionally estimated without thorough analysis, and such
estimates are often much too low. Such a low minimum drop figure erroneously
favors the selection of an equal percentage valve.

The end result is the selection of an oversized equal percentage valve that operates
in the low portions of lift even at maximum flow. Consequently, rangeability and
response at low flow conditions are lost. It is important to use realistic pressure
drop data for both valve sizing and characteristic selection.
This article has covered the basic aspects of Dresser Masoneilan Valves
Sizing concepts.

References
Feel free to download the Dresser Masoneilan control valve handbook in
pdf format.
 MASONEILAN-1998-Control-Valve-Sizing-Handbook.pdf
 FOXBORO (1975) Control Valve Characteristic Selection
 FOXBORO (1965) Valve Sizing
 FOXBORO (1979) Cv TABLES FOR V1 SERIES VALVES
 Masoneilan Camflex ii Manual

 Masoneilan Worthington Globe Valve

 Valtek Control Valve Sizing Manual