Establishing Control Valve Trim Flow Velocity

ISA04-P211 Gerald Liu, P. Eng. Engineering Associate Utilities Technology Team Syncrude Canada Ltd. Fort McMurray, T9H 3L1 Alberta, Canada liu.gerald@syncrude.com Abstract:
A method is provided for establishing a control valve trim's throttling exit flow area using readily available information in the technical literature and known process conditions in the fluid flow field. The area at the exit of the throttling trim is needed to determine the velocity and energy content of the fluid jets leaving the valve trim. The velocity and energy levels of the jets are essential in judging the ability of the valve design to provide good control while minimizing the detrimental affects of cavitation for liquids and noise for gases. Both of these effects can also lead to unwanted vibration of the piping systems. In addition, knowledge of the fluid velocity in the jets can also aid in judgments regarding erosion of valve internal components. The method requires knowledge of the valves flow coefficient, the variables used in determining the flow coefficient such as flow rate, pressure drop, fluid density and an estimate of the resistance coefficient for the valve trim. It is this later item that is not readily available from the valve manufacturer; however good estimates of the value of the resistance coefficient can be made from information available in literature dealing with flows and pressure drops through different geometries. Example calculations are provided for a number of valve trims as an aid in understanding the method.

Laurence R. Stratton Manager Technical Services Control Components, Inc. Rancho Santa Margarita, CA 92688 lrs@ccivalve.com

Herbert L. Miller, P. E. Valve Consultant Laguna Hills, CA 92653 hlmiller37@cox.net

Key Words: Control Valves, Trim flow area, Trim exit energy

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Nomenclature:
Symbol a c C D Ec f Gf K KE L N Np p Q r Description Flow area See Figure 2a Flow coefficient Diameter of flow section Passage expansion, ai+1 /ai Friction factor Specific Gravity Resistance coefficient Kinetic energy density Length of flow section Numerical constants Number of flow passages Pressure Volumetric flow rate See Figure 2a Unit mm2 Kv , Cv mm dmls dmls dmls dmls kPa mm Table 1 dmls kPa m3 /h Stk V W ?p a ? ?ref Valve stroke or travel Fluid velocity Mass flow rate Pressure drop See Figure 2a See Figure 2a Density of fluid Density of water mm m/s kg/h kPa kg/m3 Table 1

Subscript i Inlet conditions o Outlet conditions ref Reference value gc Gradual contraction ge Gradual extraction n Stage number

Introduction:
In order to calculate a fluid velocity it is necessary to know the flow area for the fluid in addition to the fluid density and the flow rate. There is a need to know this velocity so that a comparison against guideline and application criteria can be made. Throughout the fluid flow industry there are a number of criteria for the velocity of a fluid flowing through different components of a process system. These guidelines have been gleamed from feedback of experience and their application over time. Some have a strong basis such as a velocity that would cause flashing or choking but most are generally derived from extensive experience. This doesnt mean that the guidelines are not helpful but it does mean that we need to continually question and update their use so that they do not impose unreasonable constraints. The valve trim flow area is implicit in the calculations used for predicting noise radiating from the valve, Reference 1-3; however a specific orifice area is not calculated. The area needed for these predictions is represented in the definition and use of the valves flow coefficient, C, in the equations as well as the number of ports. The need for a specific area calculation is needed in order to calculate the kinetic energy density or dynamic pressure of the jet leaving the valve trim so that the energy may be checked to see if it is within the guidelines associated with successful control valve application experience. A successful application is one in which the valve performs its control function and is not damaged by erosion, vibration, cavitation and/or noise due to excessive velocities. All of these debilitating effects are caused by excessive fluid velocities exiting the valve trim or valve outlet. The valve outlet area can usually be closely estimated by simply knowing the nominal size of the valve. However, the trim exit flow area is usually known only to the valve manufacturer and is seldom published as part of the valve data sheet. Criteria for the trim exit kinetic energy density ha ve been published in ISAs Control Valves Practical Guides for Measurement and Control, Reference 4. These criteria are based on extensive experience in severe service valve applications where problems of erosion, vibration, ISA Expo2004 Page 2 of 11 Reliant Center Houston, TX

noise, and cavitation are frequent companions of high pressure drop and/or low downstream pressure. Quantitative measures of the impact of following these criteria were published in 1997, Reference 5, however there are hundreds of additional applications in which following these criteria have resulted in correcting significant control valve problems in the field. The published criteria for kinetic energy density exiting the trim are relevantly recent when compared to the general rule of thumb associated with the velocity exiting the valve body that appeared around the 1950s. Keep in mind that the valve outlet area remains constant for a given size valve, but the trim exit area changes as the valve is throttled. The fluid energy exiting the valve body is usually quite small in comparison to the fluid energy exiting the throttled valve trim. It is the high energy fluid exiting the valve trim that carries into the downstream piping and/or the valve body with damaging impact. Although some designers still apply the valve outlet guidelines their need has been replaced by the latest industry noise prediction procedures, References 1, 2. It therefore becomes necessary for the user to obtain a reasonable estimate of the trim exit flow area in order to determine if the energy of the fluid is going to meet recommended guidelines. By obtaining this calculation of area, velocity and energy at the trim exit, significant cost associated with fixing a valve problem can almost always be avoided.

The Area Relationship:

The fluid kinetic energy density is defined as follows where N is a units conversion factor shown in Table 1. KE = o V 2 2 N1 (1)

And the velocity is calculated from the Continuity Equation as shown below:
V= W Q = N 2 ?o a N 3 a

(2)

The velocity in this expression is the average outlet velocity and the density, ?o , of the fluid at the outlet of the trim. Different valve trims and the location within the trim for the velocity and other considerations in the calculation of the kinetic energy are expanded upon in References 4, 5. Average velocity is used to keep the calculations as simple as possible. If some other velocity, such as a peak velocity, was used then the acceptance criteria would be adjusted accordingly. Velocity criteria for liquids are much lower than for gases because liquid densities are much higher, resulting in higher energy levels. While the velocity limits are quite different, the kinetic energy density criteria are the same as shown in Table 2. The specification should call for the manufacturer to provide a valve trim that meets the criteria of Table 2. The most frequent unknown is the trim exit area to be used in Equation 2. There are two situations in which a user may determine this area and thus the fluid velocity and energy level.

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1. There is a problem and the valve is disassembled with the trim setting on a work bench. The user can make physical measurements of the exit ports to establish the exit flow area versus the valve travel. Once the trim outlet flow area is known as a function of valve travel, measurements of flow rates, fluid outlet properties and valve position can be used to find the fluid energy exiting the trim at minimum and at maximum flows. 2. A new valve order is being evaluated. An estimate of the resistance of the flow path is made by looking at the type of trim. The trims flow resistance and the required flow coefficient, C, can be used to find the trims outlet flow area and in turn the fluid energy exiting the trim. Table 1. Numerical Constants Constant Value 100 000 1 000 4 633 0.003 6 25 0.003 6 3.117 1 0.1 1 0.050 9 37.99 1 000 62.4 KE, ? p, ? p bar kg/m3 kPa kg/m3 psi lbm/ft3 kg/m3 lbm/ft3 kg/m3 lbm/ft3 bar kg/m3 kPa kg/m3 psi lbm/ft3 kg/m3 lbm/ft3 V m/s m/s ft/s m/s ft/s m/s ft/s D, L mm mm in. kg/h lbm/h m3 /h gpm m3 /h m3 /h gpm mm2 in2 mm2 in2 W Q a C

N1 N2 N3

N4 N5 ?ref

Kv Kv Cv Kv Cv

Table 2. Valve Trim Outlet Fluid Kinetic Energy Density Criteria Water Velocity* Service Conditions Continuous Service, Single Phase Fluid Cavitating and Multi-phase Fluids Vibration Sensitive System m/s (ft/s) 30 (100) 23 (75) 12 (40) Oil Velocity* (Gf =0.8) m/s (ft/s) 34 (112) 26 (84) 14 (45) Air Velocity* (p=7 MPa) m/s (ft/s) 105 (345) 42 (140) Kinetic Energy Criteria kPa (psi) 480 (70) 275 (40) 75 (11)

* Noise, cavitation and erosion concerns may dictate lower velocities. Duty cycles may allow more risk.

The discussion in this paper shows how to make reasonable estimates of the flow area.

Area and Flow Resistance Relationship:

The relationship between the trim exit area and the required capacity of the valve can be derived from three equations that govern the flow case. These equations are: ISA Expo2004 Page 4 of 11 Reliant Center Houston, TX

The Darcy Eq uation expresses the pressure drop as a function of density, velocity and the resistance coefficient of the flow path. V 2 f L V 2 p1 p2 = p = =K 2 N1 D 2 N1 (3)

The Continuity Equation (Equation 2 above) assures mass is conserved as the flow passes along the flow path. The required flow coefficient is defined as:

C=

Q N4

ref p

(4)

Combining Equations 2 4 results in: C= N5 a K (5)

The area is then expressed as a function of the required flow coefficient and the resistance coefficient of the flow path using Equation 5. For a circular flow path the expression in Equation 5 may be expressed in terms of the diameter of the orifice. Once the area is known, the trim exit velocity and the kinetic energy density are calculated using Equations 1 and 2. In the calculation of the velocity using these equations it is assumed that the density is constant for liquids and for gases the fluid follows the ideal gas relationship. This is true for most of the fluids encountered in general practice. Assuming near constant temperature across the trims flow path, the outlet density can be estimated from Equation 6.
o = i po pi

(6)

When choking occurs across the valve trim, the exit velocity reaches sonic velocity for the gas and remains constant. In the case of sonic flow, the outlet density must be adjusted as follows:
o = o V c

(7)

This adjusted outlet density and sonic velocity would be used in Equation 1 to find the kinetic energy density of the gas at the outlet of a choked valve trim. At this point it would appear that we have simply substituted the unknown area for an unknown resistance coefficient, which is true; however there is extensive literature developed for loss coefficients associated with flow channels used in valve trim design. ISA Expo2004 Page 5 of 11 Reliant Center Houston, TX

Resistance Coefficients:
In order to estimate the resistance coefficient for a valve trim it is necessary to know the geometry of the flow passage. Knowing the flow geometry allows one to use readily available information in the literature to derive a reasonable estimate of the total trim resistance. One of the best references for resistance coefficients is presented in Reference 6. The resistance coefficients assume a well developed turbulent flow length upstream and downstream of the restriction. This is not possible within the short length available in a valve so the actual resistance coefficients may be a bit different that the calculated. In some cases the pressure drop will be larger such as for closely coupled right angle turns (about 10 percent higher) and in some cases the pressure drops will be smaller because an expansion or contraction occurs that results in separation of the fluid from the channel walls. The error resulting from this lack of a developed flow is not significant because as seen in Equation 5, which is used to calculate the trim exit area, the square root of the resistance coefficient is used. This dampens some of the inaccuracy in the calculation. In using the required flow coefficient and flow path resistance coefficients it is assumed that the entire pressure drop occurs across the valves throttled trim and the pressure loss from flow through the body and any attached expanders or reducers is not significant. The example figures illustrate a flow area expansion between stages. An expansion also occurs for most other trim types. When this expansion is greater than 10 percent the resistance coefficient will be overstated because of significant fluid separation that causes the staging to be less effective. Thus there would be higher jet velocities than calculated by the resistance coefficient equations. For other trim types a similar approach to that shown in the three examples will work. It is particularly helpful if physical measurements can be made with the trim in hand. In some cases there is information in the vendors catalogs that will help in making the judgment as to what the outlet area would be. The area of the windows may be published along with the number of windows for a cage guided trim. For axial flow trim the plug size along with the lift can help in estimating the outlet flow area. That is; the outlet area would be the annular area between the plug diameter and the seating surface (adjust for the angle of these two interfacing surfaces.)

Examples
Three examples are presented below to illustrate the calculation of the resistance coefficient of a valve trim flow channel. Example 1: Cage Trim with venturi shaped slots Find the outlet flow area and stroke for the slotted cage shown in Figure 1. The plug lift is throttling to meet a required flow coefficient of 40. Assume there are 16 identical slots and the measurements are as shown in Figure 1a. Ignore the flow paths axial flow by assuming the flow path height matches the plugs travel and is constant from the inlet to the outlet of the flow path. ISA Expo2004 Page 6 of 11 Reliant Center Houston, TX

The valve trim with venturi shaped slots has a resistance coefficient due to the sudden contraction at the inlet, a gradual contraction to the throat, a gradual expansion to the outlet and a sudden expansion at the outlet. The resistance coefficient for the sudden contraction into the slot is 0.5 based on the inlet area. The resistance coefficient for the sudden expansion out of the slot is 1.0 based on the outlet area. Since the contraction and expansion angles are less than 45 , the resistance coefficient for the gradual contraction based on the throat area is found using (Reference 6):

a 1.59 Stk 30 = 0.104 K gc = 0.8 sin 1 1 = 0.8 sin 1 2 3.18 Stk 2 a 2

The resistance coefficient for the gradual expansion based on the throat area is found using (Reference 6):
a 20 1.59 Stk = 2.6 sin 1 1 = 2.6 sin 1 = 0.200 2 a 2 2 4.75Stk
2 2

K ge

Normalizing the loss coefficients to the outlet area and adding those yields (Reference 6):
4.75 4.75 4.75 K o = 0 .5 + 0.104 + 0.200 + 1 = 4.83 3.18 1.59 1.59
2 2 2

Equation 5 can be rearranged to find the outlet flow area,

ao =

Cv K o 40 4.83 = = 1727 mm2 N5 0.050 9

and the plug stroke is found from:

Stk =

ao 1727 = = 22.7 mm N p wo 16 (4.75 )

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Figure 1 Venturi Valve Trim

Figure 1a Venturi Valve Trim Flow Path

Example 2: Concentric Cage Trim with Offset Drilled Holes The trim consists of a plug modulating inside three concentric cages as shown in Figure 2. Each cage has a number of drilled holes in which the holes are offset in order to produce a tortuous path. Measurements of the holes and their offsets are shown in Table 3. Figure 2a shows the variables used to find the intersection area of the circles. Assuming a flow of 300,000 lbm/h of ambient temperature water (?1 = 62.4 lbm/ft3 ), a flow coefficient of 40, find the outlet flow area of the trim and the outlet velocity of the water jets.

Figure 2 Concentric Cage Trim

Figure 2a Variables for Finding the Intersecting Area Table 3. Hole Dimensions and Offset Variable ri rm ro Page 8 of 11 Dim 0.125 0.15 0.18 Units inch inch inch

Geometry Inner Hole Radius Middle Hole Radius Outer Hole Radius ISA Expo2004

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Inner to Middle Centerline Offset Middle to Outer Centerline Offset Inner Hole Area Inner to Middle Hole Area Middle Hole Area Middle to Outer Hole Area

cim cmo ai aim am amo

0.15 0.18 0.049 1 0.020 1 0.070 7 0.029 0

inch inch in2 in2 in2 in2

The angles a and and the overlap area, a, are defined by the following equations.

ri2 + ci2 ri2 +1 i = 2 cos 2r c i i 2 2 2 1 ri+1 + ci r i i = 2cos 2 r c i+1 i

1

ai =

1 2 ri (i sin i ) + ri2 +1 (i sin i ) 2

These equations are repeated for every set of overlapping flow openings. The area between the inner and middle hole works out to 0.0201 in2 and the area between the middle and outer hole works out to 0.0290 in2 . The flow coefficient for the intersecting holes is a series of sudden expansions and contractions. 1. 2. 3. 4. 5. The sudden contraction to the inner hole The sudden contraction to the area between the inner and middle hole The sudden expansion to the middle hole The sudden contraction to the area between the middle and outer hole The sudden expansion out of the area between the middle and outer hole

The resistance coefficient for the sudden contraction into the inner hole, K1 , is 0.5 based on the inlet hole area. The resistance coefficient for the sudden expansion out of the area between the middle and outer hole, K5 , is 1.0 based on this outlet area. Since the contraction and expansion angles are all sudden (? = 180 ), the resistance coefficients for the sudden contractions, based on the smaller area, are found using (Reference 6):

ai+1 K c = 0.5 1 A i K ci = 0.5 aim 0.020 1 K cim = 0.5 1 a = 0.5 1 0.049 1 = 0.295 i a mo 0.029 0 K cmo = 0.5 1 a = 0.5 1 0.070 7 = 0.295 m
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The resistance coefficient for the sudden expansion based on the throat area is found using (Reference 6):
ai Ke = 1 A i +1
2

aim 0.0201 K em = 1 A = 1 0.070 7 = 0.512 m K emo = 1

The resistance coefficient is the sum of all of the individual coefficients normalized to the same area, which in this case is the intersection area between the middle and outer holes. Normalizing the loss coefficients to this outlet area and adding yields:
0.029 0 0.029 0 0.029 0 K o = 0 .5 0.049 1 + 0.295 0.0201 + 0.512 0.020 1 + 0.295 + 1 = 3.14 9
2 2 2

Equation 5 can be rearranged to find the outlet flow area,

ao =

Cv Ko 40 3.14 9 = = 1.87 in 2 N5 37.99

The exit velocity of the water jets is found from Equation 2:

Vo = W 300 000 = = 103 ft/s N 2 ?o a o 25 (62.4 )1.87

Example 3: Trim with Expanding Right Angle Turns Develop an equation for the resistance coefficient based on outlet area for the flow channel with constantly expanding passages consisting of closely coupled right angle turns as shown in Figure 3.

Figure 3. Closely couple Right Angle Turns with Expanding Area. This trim will have a resistance coefficient for the sudden contraction at the inlet, a right angle turn coefficient for every turn and a sudden expansion at the outlet. The sudden contraction and ISA Expo2004 Page 10 of 11 Reliant Center Houston, TX

expansion coefficients are 0.5 and 1, respectively, and the right angle turn coefficient is given by Reference 6 for Mitre Bends with an angle of 90 degrees. The turbulent friction factor in the Mitre Bend equation would vary depending upon the surface associated with the flow channel however a good estimate of the resistance coefficient is 1.2. All of the coefficients would need to be normalized to the outlet area thus accounting for an expansion of the flow area after each turn. If the ratio of the flow area downstream of the turn to upstream of the turn is Ec and constant, then the equation for the resistance coefficient is given by Equation 11.
K o = 0.5 Ec8 + 1.2 Ec6 + 1.2Ec4 + 1.2 Ec2 + 1.2 + 1.0

(11)

If there are no expanding channels then Equation 11 would also work with Ec equal to one. The equation would be applicable to a combination of expanding turns and non-expanding turns with proper corrections for normalizing to the outlet area.

Conclusion:
A method for calculation the trim exit fluid velocity has been developed. Examples have been provided and a table of common valve trims developed showing reasonable values of the resistance coefficients to be used in calculating trim outlet area. These calculations will allow a user to quickly judge whether a valves trim can successfully ha ndle a problem application in the field or help to judge if it is the root cause of an existing problem.

References:
1. Control Valve Aerodynamic Noise Prediction, ISA Standard 75.17-1989, Instrument Society of America, Research Triangle Park, N. C.,1989 2. Control valve aerodynamic noise prediction method, International Standard CEI/IEC 534-8-3:1995. International Electrotechnical Commission, Geneva, Switzerland, 1995. 3. Bauman, H. D, and Page Jr., G. W., A method to predict sound levels from hydrodynamic sources associated with flow through throttling valves, Noise Control Engineering Journal, Vol. 43, September-October, 1995. 4. Borden, Guy, Jr., Control Valves Practical Guides for Measurement and Control, Instrument Society of America, Research Triangle Park, N. C., 1998, Chapter 12, Control Valve Applications, pg. 411-477. 5. Miller, H. L., and Stratton, L. R., Fluid Kinetic Energy as a Selection Criteria for Control Valves, ASME Fluids Engineering Division, Summer Meeting, Paper FEDSM97-3464, Vancouver, British Columbia, Canada, June 22-26, 1997. 6. Flow of Fluids through Valves, Fittings, and Pipe - Publication 410, Crane Co., Stanford, CT, 25th printing 1991, Appendix A, Physical Properties of Fluids and Flow Characteristics of Valves, Fittings, and Pipe, pg A26 & A27.

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