Sizing flow valves is a science with many rules of thumb that few

people agree on. In this article I'll try to define a more standard
procedure for sizing a valve as well as helping to select the
appropriate type of valve. **Please note that the correlation
within this article are for turbulent flow

STEP #1: Define the system

The system is pumping water from one tank to another through
a piping system with a total pressure drop of 150 psi. The fluid is
water at 70 0F. Design (maximum) flowrate of 150 gpm,
operating flowrate of 110 gpm, and a minimum flowrate of 25
gpm. The pipe diameter is 3 inches. At 70 0F, water has a
specific gravity of 1.0.
Key Variables: Total pressure drop, design flow, operating flow,
minimum flow, pipe diameter, specific gravity
STEP #2: Define a maximum allowable pressure drop for the valve
When defining the allowable pressure drop across the valve, you should first investigate the
pump. What is its maximum available head? Remember that the system pressure drop is limited
by the pump. Essentially the Net Positive Suction Head Available (NPSHA) minus the Net
Positive Suction Head Required (NPSHR) is the maximum available pressure drop for the valve
to use and this must not be exceeded or another pump will be needed. It's important to remember
the trade off, larger pressure drops increase the pumping cost (operating) and smaller pressure
drops increase the valve cost because a larger valve is required (capital cost). The usual rule of
thumb is that a valve should be designed to use 10-15% of the total pressure drop or 10 psi,
whichever is greater. For our system, 10% of the total pressure drop is 15 psi which is what we'll
use as our allowable pressure drop when the valve is wide open (the pump is our system is easily
capable of the additional pressure drop).
STEP #3: Calculate the valve characteristic

For our system,

At this point, some people would be tempted to go to the valve charts or characteristic curves and
select a valve. Don't make this mistake, instead, proceed to Step #4!
STEP #4: Preliminary valve selection
Don't make the mistake of trying to match a valve with your calculated Cv value. The Cv value
should be used as a guide in the valve selection, not a hard and fast rule. Some other
considerations are:
a. Never use a valve that is less than half the pipe size
b. Avoid using the lower 10% and upper 20% of the valve stroke. The valve is much easier to
control in the 10-80% stroke range.
Before a valve can be selected, you have to decide what type of valve will be used (See the list
of valve types later in this article). For our case, we'll assume we're using an equal percentage,
globe valve (equal percentage will be explained later). The valve chart for this type of valve is
shown below. This is a typical chart that will be supplied by the manufacturer (as a matter of
fact, it was!)

For our case, it appears the 2 inch valve will work well for our Cv value at about 80-85% of the
stroke range. Notice that we're not trying to squeeze our Cv into the 1 1/2 valve which would
need to be at 100% stroke to handle our maximum flow. If this valve were used, two
consequences would be experienced: the pressure drop would be a little higher than 15 psi at our
design (max) flow and the valve would be difficult to control at maximum flow. Also, there
would be no room for error with this valve, but the valve we've chosen will allow for flow surges
beyond the 150 gpm range with severe headaches!
So we've selected a valve...but are we ready to order? Not yet, there are still some
characteristics to consider.
STEP #5: Check the Cv and stroke percentage at the minimum flow
If the stroke percentage falls below 10% at our minimum flow, a smaller valve may have to be
used in some cases. Judgements plays role in many cases. For example, is your system more
likely to operate closer to the maximum flowrates more often than the minimum flowrates? Or is
it more likely to operate near the minimum flowrate for extended periods of time. It's difficult to
find the perfect valve, but you should find one that operates well most of the time. Let's check
the valve we've selected for our system:

Referring back to our valve chart, we see that a Cv of 6.5 would correspond to a stroke
percentage of around 35-40% which is certainly acceptable. Notice that we used the maximum
pressure drop of 15 psi once again in our calculation. Although the pressure drop across the
valve will be lower at smaller flowrates, using the maximum value gives us a "worst case"
scenario. If our Cv at the minimum flow would have been around 1.5, there would not really be
a problem because the valve has a Cv of 1.66 at 10% stroke and since we use the maximum
pressure drop, our estimate is conservative. Essentially, at lower pressure drops, Cv would only
increase which in this case would be advantageous.
STEP #6: Check the gain across applicable flowrates
Gain is defined as:

Now, at our three flowrates:

Qmin = 25 gpm
Qop = 110 gpm
Qdes = 150 gpm
we have corresponding Cv values of 6.5, 28, and 39. The corresponding stroke percentages are
35%, 73%, and 85% respectively. Now we construct the following table:
Flow Stroke Change in flow
Change in Stroke (%)
(gpm) (%) (gpm)
25 35
110-25 = 85 73-35 = 38
110 73
150 85
150-110 = 40 85-73 = 12

Gain #1 = 85/38 = 2.2

Gain #2 = 40/12 = 3.3
The difference between these values should be less than 50% of the higher value.
0.5 (3.3) = 1.65
and 3.3 - 2.2 = 1.10. Since 1.10 is less than 1.65, there should be no problem in controlling the
valve. Also note that the gain should never be less than 0.50. So for our case, I believe our
selected valve will do nicely!
OTHER NOTES:
Another valve characteristic that can be examined is called the choked flow. The relation uses
the FL value found on the valve chart. I recommend checking the choked flow for vastly
different maximum and minimum flowrates. For example if the difference between the
maximum and minimum flows is above 90% of the maximum flow, you may want to check the
choked flow. Usually, the rule of thumb for determining the maximum pressure drop across the
valve also helps to avoid choking flow.
SELECTING A VALVE TYPE
When speaking of valves, it's easy to get lost in the terminology. Valve types are used to
describe the mechanical characteristics and geometry (Ex/ gate, ball, globe valves). We'll use
valve control to refer to how the valve travel or stroke (openness) relates to the flow:
1. Equal Percentage: equal increments of valve travel produce an equal percentage in flow
change
2. Linear: valve travel is directly proportional to the valve stoke
3. Quick opening: large increase in flow with a small change in valve stroke
So how do you decide which valve control to use? Here are some rules of thumb for each one:
1. Equal Percentage (most commonly used valve control)
a. Used in processes where large changes in pressure drop are expected
b. Used in processes where a small percentage of the total pressure drop is permitted by the
valve
c. Used in temperature and pressure control loops
2. Linear
a. Used in liquid level or flow loops
b. Used in systems where the pressure drop across the valve is expected to remain fairly constant
(ie. steady state systems)

3. Quick Opening
a. Used for frequent on-off service
b. Used for processes where "instantly" large flow is needed (ie. safety systems or cooling water
systems)
Now that we've covered the various types of valve control, we'll take a look at the most common
valve types.
Gate Valves
Best Suited Control: Quick Opening
Recommended Uses:
1. Fully open/closed, non-throttling
2. Infrequent operation
3. Minimal fluid trapping in line

Applications: Oil, gas, air, slurries, heavy liquids, steam, noncondensing

gases, and corrosive liquids
Advantages:
1. High capacity
2. Tight shutoff
3. Low cost
4. Little resistance to flow
Disadvantages:
1. Poor control
2. Cavitate at low pressure drops
3. Cannot be used for throttling

Globe Valves
Best Suited Control: Linear and Equal percentage
Recommended Uses:
1. Throttling service/flow regulation
2. Frequent operation
Applications: Liquids, vapors, gases, corrosive substances, slurries
Advantages: Disadvantages:
1. Efficient throttling 1. High pressure drop
2. Accurate flow control 2. More expensive than other valves
3. Available in multiple ports
 Ball Valves
Best Suited Control: Quick opening, linear

Recommended Uses:
1. Fully open/closed, limited-throttling
2. Higher temperature fluids

Applications: Most liquids, high temperatures,

slurries

Advantages: Disadvantages:
1. Low cost 1. Poor throttling characteristics
2. High capacity 2. Prone to cavitation
3. Low leakage and maint.
4. Tight sealing with low torque
Butterfly Valves
Best Suited Control: Linear, Equal percentage
Recommended Uses:
1. Fully open/closed or throttling services
2. Frequent operation
3. Minimal fluid trapping in line
Applications: Liquids, gases, slurries, liquids with suspended
solids
Advantages: Disadvantages:
1. Low cost and maint. 1. High torque required for control
2. High capacity 2. Prone to cavitation at lower flows
3. Good flow control
4. Low pressure drop

Other Valves
Another type of valve commonly used in conjunction with other valves is called a check
valve. Check valves are designed to restrict the flow to one direction. If the flow reverses
direction, the check valve closes. Relief valves are used to regulate the operating pressure of
incompressible flow. Safety valves are used to release excess pressure in gases or compressible
fluids.
References:
Rosaler, Robert C., Standard Handbook of Plant Engineering, McGraw-Hill, New York, 1995,
pages 10-110 through 10-122
Purcell, Michael K., "Easily Select and Size Control Valves", Chemical Engineering Progress,
March 1999, pages 45-50
Valve Pressure Loss & Flow - Q&A and Equations
1. What does Cv factor mean? - The definition of Cv factor is the number of
U.S. gallons per minute that will pass through a valve with a pressure drop of
one (1) psi. This 'factor' is determined by physically counting the number of
gallons that pass through a valve with one (1) psi applied pressure to the valve
inlet and zero (0) pressure at the outlet. Cv is a mathematical constant. For a
pressure drop other than one (1)psi, use the formula in answer number 10 below.
2. Does every valve have a Cv factor? - No. Cv factors typically apply to full
open/full closed shut-off valves such as solenoid valves, ball valves, etc.. Valves
that are held open without aid of liquid pressure in the pipeline.
3. Which valves do not have a Cv factor? - Cv factors typically do not apply to
modulating or regulating valves, spring loaded check valves, etc. that
incorporate a control spring since more than one (1) psi is required just to begin
to position such valves.

4. What is Delta P? - A commonly used term, Delta P or its symbol usually

refers to the pressure drop across a piping component such as a valve or filter.
" " (from the Greek Delta) is the 'change' in something; in this case a change,
or drop, in pressure. To determine the Delta P across a valve, simply subtract the
outlet pressure (P2) from the inlet pressure(P1).

The equation is P1-P2 =

5. Why is pressure drop important? - Pressure drop is a critical element in valve

sizing and valve application. Pressure drop must be known by the engineer
designing the system to ensure proper valve selection.
6. What factors determine pressure drop across a valve? - The most critical
factors are the orifice size and internal flow path. An example would be a full
port/full open 1" ball valve with a typical Cv of 40 versus a full open 1"
diaphragm valve with a typical Cv of 15.
7. What is Back Pressure? - Back pressure is simply defined as the pressure
found at the outlet or "back" of a valve. It is caused by downstream restrictions.
8. What creates back pressure & why is it important to know? - Resistance to
flow in piping systems creates back pressure. Piping components such as spray
nozzels, filters, reducing fittings, all can contribute to both back pressure and
pressure loss. It is important to know the back pressure present (or potential) in a
piping system when installing or specifying a valve since many valve designs
can be adverely affected if their maximun ratings are exceeded.
9. What is the relationship between the flow rate (GPM) and pressure drop? -
Pressure drop and flow rate are dependent on each other. The higher the flow
 rate through a restriction, such as a valve, the greater the pressure drop.
Conversely, the lower the flow rate, the lower the pressure drop.

10. How do the GPM, Cv factor, and work together to size a valve? - At
least two of these elements are necessary to properly specify a valve. Here are
the flow formulas.

Where G = Specific Gravity of the Fluid

5 Most Common Mistakes When Specifying Valves

As the old saying goes, "If you have enough time to do something over again, you had enough time to do
it right the first time."
Today business moves at a highly accelerated rate, particularly in the process industries, compared to
even just a decade ago. Customers often demand that product be shipped overnight, spending exorbitant
amounts of money on priority freight. And in an effort to accommodate the customer, most salespeople do
not question the application for which a component(s) will be used. If pipe or fittings are being ordered,
this does not usually create a problem. But when valves are concerned, this lack of scrutiny can result in
problems of nightmarish proportions.
It behooves all parties involved to ask a few simple questions, and prevent the mistakes that can lead to
disaster in a flow control system...
The Top Five Mistakes
1. The Name Game: Too many synonyms!
This is a case of "You say 'po-tay-to' I say 'po-tah-to'." Take pressure regulators, for example.
Somebody might call it a "pressure sustaining valve," still another might know it as a "pressure
reducer valve."
To muddy the waters even further, backpressure regulators are commonly mistaken for pressure
regulators. The backpressure regulator is a normally closed valve installed at the END of a
piping system to provide an obstruction to flow and thereby regulate upstream (back) pressure.
This valve is called upon to provide pressure in order to draw fluid off the system. The pressure
regulator is a normally open valve and is installed at the START of a system or before pressure
sensitive equipment to regulate or reduce undesirable higher upstream pressure.
Because of this "name game," a normally open pressure regulator is sometimes installed to
perform as a backpressure regulator, where it simply passes the fluid to the return tank and
therefore does not maintain any pressure upstream.
Solenoid valves are often misapplied as well. Generally, a solenoid valve is required to default to
a desired position, referred to as fail-safe, upon loss of power. In the case of a two way valve,
either closed or open, or a three way valve, either left port or right port. Even the relatively
universal "energize to open" is ocassionally mis-ordered as "normally open." In some of these
cases the process control system will compensate for the one valve operating improperly, but in
the event of a power loss the results might be disastrous.
The question to ask: What is the valve to accomplish? In the case of a "pressure regulator," will it
be used to control pressure downstream or upstream? Is that actuated valve need to shut off or
divert flow? Understand and write out precisely what function the valve is to perform.
2. Irreconcilable Differences: Media and Material
"If PVC works so well with water, why is my system is falling apart?!" So we ask: "Are there
any impurities in your water?" The reply: "Of course not...and we keep it right at the boiling
point!"
Even though this example sounds too absurd to be true, less obvious but equally ludicrous "time
bombs" are installed around the world with alarming regularity.
Material compatibility is critical to the safe operation of a system and personnel safety. The
result of a material misapplication can be catastrophic. Corroding pipe and valves can cause
chemical leaks, which may injure workers, cause productivity losses and require reporting to
OSHA and the EPA. Additional expenses for clean up of the chemical spills and fines may also
be expected.
Proper material compatibility analysis requires knowledge of the type, concentration and
temperature of fluid(s) being handled and the valve body and seal material. Every materials
manufacturer publishes an easy to use chemical compatibility chart, which takes the guesswork
out of specifying compatible materials. Unfortunately, anxious designers are notorious for
ignoring the published temperature ratings of valve and seal materials, assuming that they all
have a built in safety factor.
3. Size Matters...But Sometimes Pressure Matters More
If the pipe diameter is 2", most people assume that a 2" valve will do the job. In a few cases,
that's true. But in general, pressure considerations are of utmost importance in a piping system,
and therefore critical when specifying a valve. Unfortunately, there are no industry-wide
standard pressures for valve sizes; no two manufacturers design a 2" valve the same way, and
different designs have different pressure considerations.
Outlet pressure, for example, is critical to solenoid valves but frequently overlooked. If
downstream pressure sufficiently exceeds the valve's outlet pressure rating, the core spring may
not be powerful enough to close the valve. In the case of a pilot-operated solenoid valve,
however, an unusually low inlet pressure can be just as problematic: If the pilot valve requires 5
psi pressure drop (delta P) to operate the main orifice, and the system has only 3 psi, the valve
may not open.
The factors to consider before specifying a valve are minimum and maximum inlet pressures,
minimum and maximum differential pressure, outlet or backpressures and set pressure.
4. The Autobahn in Disguise
Velocity is very often overlooked when specifying a valve. Unlike that famous European
roadway, a piping system does have a "speed limit." The generally accepted safe velocity for a
thermoplastic piping system is 5 feet per second. But like the pace of today's business
environment, a "slow" 5 ft/second process system just isn't productive enough! Unfortunately, it
is becoming the rare exception to the rule.
At higher velocities, such as an ultra-pure water system in a semiconductor fab facility, an
improperly selected valve can easily create a water hammer situation if it closes too quickly. This
dangerous energy surge travels at the speed of sound and frequently causes damage to pipe,
fittings, valves, and instrumentation.
A classic example of this happened in a reverse osmosis water system at a major New York City
hospital. Water was piped down to a sub-basement from storage tanks on the 16th floor. As the
r.o. water was needed, a ball valve was opened, which ultimately fed a tiny gooseneck faucet.
Unfortunately, the system designer didn't take the 16 floors of head into consideration. Every
time the ball valve was opened, water slammed into the constriction caused by the gooseneck
faucet, which resulted in a dangerous water hammer back through the system.
The problem could've been prevented with a little planning: Always consider liquid velocity, and
valve closing time.
5. Letting the Electric Slide
Neglect of actuator voltages and electrical enclosure types is not quite as common as the
mistakes above, but often creates the most headaches and is potentially the most dangerous.
If an incorrect voltage is specified on a solenoid valve or a valve actuated by an electric motor, it
will not operate properly. Often the actuator or coil will overheat, and may cause a fire.
NEMA ratings on electrically actuated valves are designed to provide for safety. NEMA has
ratings for many types of electrical enclosures for a variety of environments. Most common are
general purpose, water tight, corrosion resistant, and explosion proof. Specifying the wrong
enclosure type may endanger personnel and property.
In Review...
Too often, valves are purchase by pipe size and without enough consideration for pressure, flow,
chemical compatibility, performance, or safety factors. The mistakes listed above are just the
most common—and most obvious. To properly specify a valve, all components and aspects of
the system should be taken into consideration.
About the Author: Andy Ryan has 19 years of experience in the flow control field, primarily
with valves and related instrumentation. Mr. Ryan has had numerous articles published on
valves, and is recognized as an industry authority on thermoplastic valves and piping systems.
He is the Technical Sales Manager for Plast-O-Matic Valves, Inc., Cedar Grove, NJ