Valve Flow Characteristics

The discussion begins with control valve flow characteristics (the relationship between valve opening and
flow). Actually, a control valve has two characteristicsan inherent characteristic and an installed
characteristic.
The inherent characteristic of a valve is the characteristic published by the manufacturer, based on tests
performed in a system where great care is taken to ensure that the pressure drop across the test valve is
held constant at all valve openings and flow rates. The inherent characteristic, therefore, represents the
relationship between valve flow capacity and valve opening when there are no system effects involved.
Figure 1 shows the ideal inherent characteristics of the two most common flow characteristics, the linear
and equal percentage. The source of the name of the linear characteristic is
self-evident from the graph.
The name of the equal percentage characteristic comes from the definition:
Equal changes in valve position cause equal percentage changes in flow.
The result, as shown in Figure 1, is a characteristic where a small increment
of valve position at small openings results in a small increase in flow
capacity, while the same increment of valve position at large openings
results in a larger increase in flow capacity.
Most control systems give the best performance when they behave in a
linear manner. In light of this fact, the question might be asked, Why would
you use an equal percentage valve which is not at all linear? The answer is
because of the installed characteristic. The installed characteristic is the
relationship between valve position and flow in the specific system being
considered, taking into account any changes in the pressure differential
available to the control valve due to the flow squared relationship between Figure 1. Linear and equal percentage
inherent characteristics
flow and piping pressure losses and/or the behavior of a centrifugal pumps
head curve.
The majority of fluid process systems include a significant amount of pipe and other pressure-consuming
elements (elbows, pipe reducers, isolation valves, heat exchangers, pumps whose pressure decreases with
increasing flow, etc.). This results in a relationship between system flow and pressure differential available
to the control valve similar to the lower curve of Figure 2.
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While referring to Figure 3, one must imagine a control valve with an
inherent equal percentage characteristic installed in a system that has a
characteristic like the lower curve of Figure 2. When the control valve is
wide open, the flow will be at its maximum value. Moving the control valve
in the closing direction of course causes the flow to decrease. As soon as
the flow starts to decrease, it can be seen from Figure 2 that the pressure
differential across the valve increases, resisting the decrease in flow
through the valve. The result of this interaction between control valve and
system produces a nearly linear installed characteristic and thus the
popularity of the equal percentage flow characteristic and the fact that
equal percentage valves are specified about 90 percent of the time.
Because the equal percentage curve and the pressure drop curve are not
exact mirror images of each other, the installed characteristic of an equal Figure 2. Valve pressure
percentage valve in a system with a lot of pipe is not perfectly linear, but drop vs. flow
has a slight S shape as shown in Figure 3. Sometimes it will not be as
symmetrical as shown. As a general rule, systems with a significant amount of pipe and/or other pressure-
consuming elements (the most common case) are best suited to equal percentage inherent characteristic
valves.
When a control valve is installed in a system with very little pipe and/or other pressure-consuming
elements, the pressure differential across the valve remains constant, or nearly constant, with changes in
flow as shown in the upper graph of Figure 2. The situation is similar to the way valve manufacturers
determine the inherent characteristics of their valves. Since the pressure differential across the valve
remains constant with changes in flow, the installed characteristic will be the same as the valves inherent
characteristic. In the case of a system where the pressure drop across the control valve remains constant
with changes in flow, a valve with a linear inherent characteristic will also have a linear installed flow
characteristic. As a general rule, systems without a significant amount of
pipe and/or other pressure-consuming elements are best suited to linear
inherent characteristic valves.
The symptom of a misapplied control valve flow characteristic is a control
loop that only gives good control at one end of its operating range and is
either sluggish or becomes unstable at the other end of its operating range.
An example of a misapplied valve inherent flow characteristic would be an
equal percentage valve in a system with very little piping. The left-hand
graph of Figure 4 shows the resulting non-linear (equal percentage)
installed flow characteristic, which is very undesirable.
Upon start up of this system, if it was running at a low process load, the
valve was around 25 percent open (Point 1) and after going through the
process of tuning a PID controller, one can see that the slope of the valves
installed characteristic curve is quite shallow, meaning that the valves gain
(or the sensitivity of flow to changes in valve position) is quite low. To make Figure 3. Installed
up for this, the proportional gain of the controller would need to be set characteristic of an equal
fairly high. As expected, when one makes a step change in the set point, percentage valve in the
there is a quick and stable response. Later, when the process load has system with lots of pipe and
increased, the valve might be around 50 percent open (Point 2). other pressure-consuming
At this point, the slope of the valves installed characteristic curve (its gain) elements of Figure 2.
is higher meaning that the value of controller proportional gain previously
selected is higher than it should be when the valve is 50 percent open. When the set point is stepped up
from the current 50 percent position there is an oscillatory response. When the process load increases to
where the valve is around 75 percent open (Point 3) the slope of the valves installed characteristic curve is
quite steep, meaning that the valves flow gain is quite high. The value of controller gain originally selected
when the valve was 25 percent open is now much too high, and when the set point again is stepped up
there is a very unstable response. If the loop were instead tuned when the control valve was 75 percent
open, a lower value of proportional gain would have been used, and there would be a fast, stable response
to a step change in set point. However, if operated at lower loads, the response would be very sluggish.
If one had misapplied a linear valve in a system with a lot of pipe, the situation would be the opposite of
what is shown in Figure 4. Just as the system with a lot of pipe pushes the equal percentage inherent
characteristic upward into a linear installed characteristic, it would push a linear inherent characteristic
upward into a quick-opening characteristic. With a quick-opening characteristic, a small increment of valve
position at small openings results in a large increase in flow capacity, while the same increment of valve
position at large openings results in a small increase in flow capacity. This system would be very sensitive
at low valve openings and very insensitive at large openings. The system would still be difficult or
impossible to tune so as to get fast stable response throughout the flow range.
On the other hand, a properly applied control valve inherent characteristic (an equal percentage valve in a
system with a lot of pipe, or a linear valve in a system with little pipe) results in a linear, or at least nearly
linear installed characteristic, as shown in the left-hand graph of Figure 5. A linear installed characteristic
gives responsive and stable control throughout the entire flow range. This properly applied valves installed
flow characteristic has a slope (and sensitivity of flow to changes in valve position, that is, its flow gain) that
is quite constant throughout the entire flow range. Regardless of what the operating point was during the
controller tuning process, the PID tuning parameters selected would be appropriate at all points in the
operating range.

Proper Valve Sizing

Next, its important to understand the importance of proper control valve
sizing. If the right size valve is not selected, there are two possibilities: (1)
The valve may too small. If it is, it wont be able to pass the required flow. In
actual practice, undersized valves are fairly uncommon; (2) The valve may
be too large, which turns out to be all too common. An oversized control Figure 4. The non-linear
valve will cost more than is necessary, although that is only a minor point installed flow characteristic
compared to the real problem. The real problem with an oversized valve is caused by a misapplied
that it will be very sensitive, meaning small changes in valve position will inherent control valve flow
cause large changes in flow. This will make it difficult, or even impossible, characteristic yields a
for it to adjust exactly to the required flow. system than cannot
Figure 6 shows graphs of the installed characteristics of two different valves maintain proper controller
in the same system. These are both segment ball valves, which have equal tuning throughout the entire
percentage inherent characteristics, and the system has a lot of pipe. Note flow range.
that up to the specified maximum flow rate of 550 GPM both have
reasonable linear installed characteristics. The 3 valve is a properly sized valve and the 6 valve is an
oversized valve. The reason that the 3 valve is a properly sized valve is
because it meets the criterion of the rule of thumb of being between 60
percent and 80 percent open at the maximum required flow of 550 GPM.
This rule of thumb has served valve users well because it gives a good
balance between using as much of the valves control range as possible,
giving good flow resolution, while providing adequate safety factor. (The 3
valve can increase flow about 20 percent above 550 GPM which should be
adequate, while the 6 valve can increase the flow about 60 percent above Figure 5. The linear or
550 GPM, which is more than should ever be required.) nearly linear installed flow
Starting at 550 GPM, if the properly sized valve opens by 1 percentage point characteristic that results
the flow will increase by 8 GPM. If the oversized valve opens by 1 from a properly applied
percentage point the flow will increase by 20 GPM. inherent control valve flow
All valves exhibit a certain amount of stickiness. After a valve has been in characteristic gives good
service for a long time, especially if someone has been a little overzealous control with stability
in adjusting the packing, it is not unusual to find that the smallest throughout the control
increment that the valve can move is 1 percent. If the best each of these range.
valves can do is position themselves in 1 percent increments, the 3 valve
will be able to control flow within 8 GPM increments, and the 6 valve will only be able to control flow
within 20 GPM increments. In general, the more oversized a control valve is, the poorer the accuracy of
control will be.
Although not always possible, it is also preferable to have the minimum
opening no less than 20 percent to provide some safety factor at the low
end. Normally, control valve manufacturers publish Cv values in 10 percent
increments beginning at 10 percent open, so its impossible to know what
happens to the Cv below that point. It is also not uncommon for the
inherent characteristic to start deviating from the ideal somewhere below
20 percent open.
It is not unusual to find properly sized full-ball, segment-ball and high-
performance butterfly valves that are two sizes smaller than the line and
properly sized globe valves that are one size smaller than the line. This is
not a rule, but just the way things often turn out. If a valve is sized, and it
turns out to be different than these, it is a good idea to check the work. A
mistake may have been made. Additionally, the person who sized the pipe
Figure 6. Comparison of a
may have made a mistake.
properly sized control valve
Most people consider it poor piping practice to use a control valve that is
and an oversized control
less than one half the line size or larger than the line size.
valve
Here are some points to remember:
If a set of loop-tuning parameters only works at one end of the control range and not the other, the
valves flow characteristic is most likely the wrong one
If a system has a lot of pipe and/or other pressure consuming elements, or a pressure source that
decreases with increasing flow, an equal percentage valve will usually be the best choice
If a system has very little pipe and/or other pressure-consuming elements and has a pressure
source that doesnt decrease with increasing flow, a linear valve will usually be the best choice
A control valve that is sized to operate around 60 percent to 80 percent open at the maximum
required flow and not much less than 20 percent open at the minimum required flow will give the
best control
Oversized control valves are very common

Process variability refers to any unwanted variation in whatever an operator is controlling flow,
pressure, temperature, level, etc. The reason it is important that these controlled variables do not
significantly change is because they can appear as changes in the properties or quality of the end product.
If a variability problem is present, there are a couple of ways to address it. One strategy is to make the
product exceed specification. For instance, the thinnest spots in a roll of paper are still thick enough. The
problem lies in the idea of giving away free product, and in todays competitive market, most cannot afford
to do that.
If a poor-quality product is made, it will either need to be sold for less, recycled (run a hydrocarbon back
through a column or reactor, or re-pulp a roll of paper), which uses energy and time and is therefore
expensive, or just sell it and hope nobody notices. If customers discover they are getting a low-quality
product, they will start buying from someone else.
Another potential result of excessive process variability is that in order to make an acceptable product, the
average throughput must be reduced. There is also the potential for putting extra stress on the control
valve, other valves, or other process equipment, which could result in otherwise unnecessary maintenance
and unscheduled downtime. In any case, process variability can cost money.
There are a number of things that can cause excessive process variability including the following:
Composition of incoming raw materials
Composition of incoming additives
Process equipment
Process control design
Inadequate mixing/agitation
Ineffective tuning of control loops
Improperly selected or poorly performing control valves
The end-users are concerned with all of the items on this list, but for this discussion the last one will be
addressed. Roughly half the time there is a variability problem, it can be traced to the control valve.
For good control, a valve is required that:
Has its flow characteristic selected to match the process
Is properly sized
Has good static and dynamic performance
In Part I of this article, the importance of selecting a valve with an inherent characteristic that matches the
process and proper valve sizing was discussed.
An improperly selected inherent flow characteristic will result in a non-linear installed flow characteristic.
The result is a system that will be difficult or impossible to tune for fast, stable response throughout the
required flow range. On the other hand, a properly selected inherent flow characteristic will yield a linear,
or nearly linear, installed flow characteristic, making it easy to tune the system for fast, stable response
throughout the entire required flow range.
Furthermore, oversized control valves have trouble accurately adjusting the flow to the desired rate.
Assuming two valves have the same amount of stickiness, a properly sized valve will be able to adjust the
flow in smaller increments (versus an oversized valve) and therefore be able to control the flow more
accurately.
Control valve performance also has a major impact on the valves contribution to process variability. The
most important measures of performance are resolution (or sensitivity), dead band, and speed of
response.
An example of a typical test for dead band and resolution is shown in Figure 1. The sticky behavior of
valves is often referred to as stiction. It is the result of the interaction between static friction and dynamic
friction. Static friction is usually much higher than dynamic friction. As a result, a valve tends to stick in
place until enough pressure builds up in the actuator to break the static friction, then the valve moves
quickly to the new position. Resolution is a measure of the smallest movement that a valve is capable of in
the same direction. This is called a static test, because one must always wait long enough after each step
for any possible movement to take place. No measurements are made while the valve is moving, but only
the valves static position is recorded after it has come to rest.

Figure 1. Typical results of a

static dead band and
resolution test.

The control signal is stepped in one direction in very small steps. After each step there is a waiting period
to make sure there is time for the valve to make any move it is going to make before the next step is
initiated. Observing the number of control signal steps that are required to make the move indicates how
sensitive the valve is, commonly referred to as resolution.
After a number of steps in the same direction, the direction of the steps is reversed. Observing the number
of steps required to initiate reversal of valve motion indicates what the dead band is.
In this example, the step size is %. In the same direction, this valve responds to each % step, so it has a
sensitivity or resolution of at least %. Upon reversal, it took two of the % steps before the valve started
moving in the reverse direction, so this valve has a dead band of no more than %. Dead band shows up in
the process as dead time, which is destabilizing to control. Note that the scales for the input and position
are different so that the two graphs will be easier to differentiate from each other.
 Figure 2. Static dead band
and resolution test of an
excessively sticky valve.

Figure 3. Limit cycle.

Figure 2 shows the test results for a very sticky control valve. The result of excessive stiction in a closed
loop control system is a limit cycle and process variability. See Figure 3 for an example of a limit cycle. Look
at the process variable trace in the figure and the horizontal line that has been drawn over the process
variable trace at the left side of the graph. The valve is stuck and the process variable is above set point.
The integral (or reset) action of the PI (Proportional plus Integral) controller ramps the controller output in
an attempt to correct the error until enough pressure builds up in the actuator to break the static friction.
Because dynamic friction is lower than static friction, the valve moves quickly to a new position. Before the
static friction broke, enough pressure had built up in the actuator that the valve overshot the target
position and the new process variable value is now below set point. As a result the PI controller reset
action now starts ramping the controller output in the opposite direction in an attempt to correct the new
error, but the valve is stuck again and does not move until enough pressure builds up in the actuator to
break the static friction. The result is a Limit Cycle.
The characteristic of a limit cycle is that the process variable oscillates in an approximate square wave
fashion and the controller output oscillates in a saw tooth wave fashion. Loop tuning will change the
period of the limit cycle, but will not eliminate it. The only fix for a limit cycle caused by a control valve is to
repair or replace the valve.
Another important measure of control valve performance is the speed of response to step changes in the
control signal. This is a dynamic test because it determines what the valve is doing while it is moving, and
the entire movement is recorded.

Figure 4. Typical control

valve response to a step
change in control signal.

Figure 4 is a typical response of a valve to a step change in set point.

There will be some dead time (Td) before anything happens. There may or may not be overshoot.
In the past, two parameters were commonly used to measure speed of response, T63, the time required
for the valve to respond through 63 percent of its total response, and T98, the time required for the valve
to reach 98 percent of its final position.
T63 was chosen as being the equivalent of the time constant of a first order system. The word time
constant was not used because control valve response is rarely first order.
For reference, a first order response with a T86 (two time constants) and settling time, similar to the T86
and settling time of the valves response, has been drawn in to emphasize that the valve response is not
first order.
ISA S75.25.01, Test Procedure for Control Valve Response Measurement from Step Inputs, now uses a
single parameter, T86 (which corresponds to two time constants of a first order system). (Note that T86 is
measured from the time of the step change in control signal.)
The speed of response of a control valve is also a concern. Figures 5 and 6 show the response of a first
order system that has a time constant of 10 seconds, that is, a process that responds through 63 percent
of its full response in 10 seconds.
 Figure 5. Response of a
process with a 10-second
time constant when
controlled by a value with a
10-second time constant.

Figure 6. Response of a
process with a 10-second
time constant when
controlled by a value with a
1-second time constant.

Although control valve response is usually more complex than first order, it is allowable, for the sake of
comparing the effect of valves with various speeds, to treat them as first order systems.
If a valve with a 10-second time constant controlled the 10-second system, the overall response would be
as shown in Figure 5. The combined response is much slower than what the process is capable of by itself.
When a valve with a 1-second time constant, as shown in Figure 6 controls the same 10-second process,
the combined response is nearly as fast as the speed with which the process could respond with an
infinitely fast valve.
Typically, a valve that is five times faster than the process will have little effect in slowing the process from
responding as quickly as it is capable of.
Below are some guidelines for valves in processes where very good control is required:
I. Resolution (stiction): 0.5%
II. Dead band: 0.5%
III. Speed of response:
A. Fast loops:
1. Valve Td 20% of desired closed loop process time constant
  2. Valve T86 40% of desired closed loop process time constant (This is equivalent to
saying that the valve should be five times faster than the desired closed loop process response time.)
3. Valve settling time desired closed loop process time constant
B. Slow loops: Not important
IV. Step overshoot: 20% maximum
Twenty percent overshoot means 20 percent of the step size. For example, the overshoot for a 10 percent
step should not exceed 2 percent of scale. The recommendation for T86 agrees with suggestions in the ISA
valve performance technical report, ISA TR75.25.02.
Figure 7 is included to demonstrate why the recommended speeds of response criteria make sense.

Figure 7. Valve response

compared with process
equipment.

This is the same valve discussed earlier, and it just meets the above guidelines for a process where the
desired closed loop time constant is 5 seconds.
The dead time is just under the recommended 20 percent of the desired closed loop time constant,
meaning it is over in time to have little impact on the overall process response.
The valve reaches 86 percent of its full travel after only 40 percent of the desired closed loop time
constant. It can be seen that the valve is way ahead of when the process needs to reach 63 percent of its
final value, and even farther ahead of when the process needs to reach its two time constants (86 percent)
value. Because the valve reaches 86 percent of its total response in 2 seconds, and the desired process
response should reach 86 percent of its total response in 10 seconds, it is equivalent to saying that the
valve is fives times faster than the desired process response time.
At the early stage of the full response, a small overshoot will contribute very little, if anything, to an
overshoot in the process.
The valve response has settled to its final value after slightly less than one desired process time constant,
long before the process is expected to reach its final value.
Things to remember:
An oversized valve will make it difficult to adjust the flow precisely.
A control valve with the wrong inherent flow characteristic will result in a non-linear installed flow
characteristic and make it difficult or impossible to find a set of PID control parameters that give
quick and stable control throughout the required flow range.
A limit cycle is most likely caused by a valve that has excessive static friction (stiction) and needs to
be repaired or replaced.

Control valve installed gain

The left graph in Figures 1 and 2 is a control valves
hypothetical installed flow characteristic, and the right
graph is the corresponding installed gain. The gain of a
device is defined as the ratio of the change in output to
the corresponding change in input. In the case of a
control valve, the output is the flow in the system (q)
and the input is valve travel (h), meaning its installed
gain is defined as: Gain = q/h. The graphical
interpretation of the installed gain is the SLOPE of the
installed flow characteristic, and the mathematical
interpretation is that the installed gain is the first
derivative of the installed flow characteristic.

The green line in the left graph of Figure 1 represents an

ideal linear installed flow characteristic where the ideal
linear installed characteristic is a straight line, and
changes in relative valve travel (h) cause equal changes
in relative flow (q). In the figure, a change in valve
position of 1 percent causes a change in flow of 1
percent. Because the slope of the green line is constant,
it follows that this valves installed gain will be constant,
and because a change in position of 1 percent causes a
change in relative flow of 1 percent, its installed gain is
Figure 1. The installed flow characteristic and
1, (gain = 1%/1% = 1.0). So just as the green line in the
installed gain of three control valves
installed characteristic graph represents the ideal linear
installed flow characteristic, the green line in the installed gain graph with a constant value of 1.0
represents the ideal installed gain.

Its impossible to get the exact ideal installed characteristic and installed gain because: (1) real valves do
not have exact linear or equal percentage inherent characteristics; and (2) the interaction between the
equal percentage inherent characteristic and the system characteristic do not exactly cancel each other.
However, one strives to get as close as possible. This is why the perfectly linear installed characteristic and
the constant installed gain of 1.0 are the benchmarks.

In Figure 1 there are two other valves with straight line installed flow characteristics. One has a very steep
slope and the other a very shallow slope.

The valve with the blue graph, whose installed characteristic has a steep slope, is a very sensitive valve. Its
installed gain graph has a constant, but large value.

The valve with the red graph, whose installed characteristic has a shallow slope, is a very insensitive valve.
(In the figure, only the portion of the valves characteristic that we are concerned with is shown.) Its gain
graphs as a constant, but small value. Neither of these valves would make a very good control valve. The
low gain valve would not make a good control valve because when the valve stem moves, the flow hardly
changes at all. A control valve that, when it moves, does
not change the flow is not much of a control valve. The
valve with the steep slope has a very high gain, meaning
that small changes in valve position cause very large
changes in flow. It is less obvious why this valve would
not be a good control valve. When two parts (such as a
ball and a seat, or a valve shaft and packing) are in
contact with each other, they exhibit two kinds of
friction. When the parts are not moving, they tend to
stick together and the friction is high. When they are
moving the friction becomes much lower. The
interaction between static and dynamic friction makes it
very difficult to position a valve exactly where it needs to
be. From the definition of gain, the change in flow is
equal to the change in position multiplied by the
installed gain (q = h * Gain). If the high gain valve
(installed gain of 4) could only be positioned in 1 percent
increments, the most accurately that flow could be
controlled would be in 4 percent increments, which
might not be accurate enough

Understanding the meaning of installed gain, how does

one apply this concept to an equal percentage valve
installed in a system with a lot of pipe (and/or other
Figure 2. Installed flow characteristic and
pressure-consuming elements), where the installed
installed gain of an equal percentage valve in a
characteristic is nearly linear but slightly S shaped, as
system with a significant amount of pipe and/or
shown in the left graph of Figure 2? The dashed lines
other pressure consuming devices.
represent the hypothetical ideal linear installed
characteristic and the resulting ideal installed gain with
a constant value of 1.0. Here the shape of the installed characteristic graph is constantly changing, and its
slope is as well. Consider the instantaneous slope (and thus the installed gain) at several points.
At Point 1, a line has been drawn that is tangent to the installed characteristic to represent the
instantaneous slope of the installed characteristic (and thus the installed gain) at Point 1. This tangent is
not as steep as the ideal linear installed characteristic, and therefore the gain is less than the ideal 1.0. A
point has been placed on the installed gain graph (Point 1) that is less than the ideal gain of 1.0.

At Point 2, if one were to draw a tangent to the installed characteristic graph, it would be parallel to the
ideal linear graph. This means, at Point 2, the instantaneous gain is 1.0, and a corresponding Point 2 is
placed on the installed gain graph at a gain of 1.0.

If one continues drawing tangent lines at Points 3, 4 and 5, the corresponding Points 3, 4 and 5 on the
installed gain graph are achieved.

Typically, the installed characteristic and installed gain graphs of equal percentage valves in systems with a
lot of pipe (and/or other pressure consuming elements), which is the most common case, will have shapes
similar to those in Figure 2, but not necessarily as symmetrical as shown in the figure.

Control valve installed gain recommendations

Below are recommendations (and the rules that Nelprof, the Metso control valve sizing and selection
software, uses when selecting the best valve size for an application) for gain magnitude and variation.

Within the specified control range:

1. Gain > 0.5

2. Gain < 3.0

3. Gain (max) / Gain (min) < 2.0

4. As constant as possible

5. As close to 1.0 as possible

Within the specified control range (by definition the system will not be controlling outside this range so one
is not concerned with what happens there), that is between the minimum and maximum required flow
rates, the gain should not be less than 0.5 or greater than 3.0. Remember the definition of gain is the
change in flow equals the change in valve position multiplied by the gain (q = h * Gain). If the gain is too
low, when the valve moves, the flow hardly changes. This means the valve will not be effective in
controlling flow. If the gain is too high, small errors in valve position will result in large errors in flow,
making it difficult or impossible to control accurately.

Typically, if the gain changes by not much more than a 2-to-1 ratio, it will be possible to come up with one
set of PID tuning parameters that will result in good control and stability throughout the required flow
range. As the variation in gain within the specified flow range becomes larger, it will become more difficult
to tune the system for both stable and good control.

When selecting the best valve out of several that meet the first three criteria, criteria 4 and 5 should be
considered. The gain should be as constant as possible. The more constant the gain, the more aggressive
the PID tuning can be without the danger of instability. The gain should also be as close to 1 as possible.
 Figure 3. Selecting the best control valve for a Figure 4. Installed flow characteristic of a 6 and a
particular system. 3 segment ball valve in the system of Figure 3.

Usually, when comparing the installed gain of different valves for the same application, as the gain
becomes more constant, it also comes closer to 1.

Selecting the Best Valve Based On Installed Gain

There is a control valve sizing program which, based on a database of actual valve inherent characteristics,
along with some user-supplied information about how the system pressure drop changes with flow, can
calculate and graph the installed flow characteristic of a particular type and size valve in its particular
system. Next, the program calculates the first derivative of the installed flow characteristic and graphs it as
the installed gain. In order for the program to define the process model, at least two flow points (maximum
and minimum required flow) are required along with the associated values of pressure upstream of the
control valve, P1, and the pressure drop across the control valve, P.

Using this software one can demonstrate how an analysis of installed gain can help select the best control
valve for a particular system. The demonstration is based on the system shown in Figure 3. The graph in
Figure 3 shows how P1, P2 and P vary with flow as modeled by the software. The goal is to select a valve
whose installed gain does the best job of meeting the installed gain recommendations given above. For
this example, things like choked flow, noise and velocity do not affect the selection, allowing one to
concentrate on installed gain.
 Figure 5. Installed flow characteristics of the
valves in Figure 4 plotted to show the true Figure 6. Installed gain of a 6 and a 3 segment ball v
relationship between their fully open flow rates al ve in thes system of Figure 3.
and sensitivity to changes in valve travel.

Figure 4 shows the installed flow characteristics of two valves being considered for the application, a 6
segment ball valve and a 3 segment ball valve. Emphasis has been added to the portions of the installed
flow graphs that are within the specified flow range of 80 to 550 gallons per minute. Because segment ball
valves have an inherent equal percentage flow characteristic and because the system is one where valve
pressure drop decreases with increasing flow, it is not surprising that the installed flow characteristics are
very nearly linear (especially within the specified flow range). This computer-generated graph shows how
linear the installed characteristics are and how much safety factor is at each end of the required flow
range. However, because the vertical scale is normalized to show actual flow divided by the fully open flow
for each valve, when comparing several valves for the same application, one cannot see the differences in
the steepness (slope) of the graph and thus the sensitivity to changes in valve position. If the data in Figure
4 were plotted on a GPM scale, instead of flow divided by fully open flow, it would look like Figure 5 where
the relative steepness of different valves can be clearly seen. The program uses a graph like Figure 5,
where the gain is calculated based on the maximum required flow, qmax, that is Gain = (q/q ) / h. Note
max

that this graph on a GPM scale is not visible to the user.

Figure 6 shows the installed gain of the same two valves. Again, emphasis has been added to the portion of
the graphs that are within the specified flow range of 80 GPM to 550 GPM. Examining the two graphs, it is
immediately clear that the 3 valve is the best choice because it meets all of the above installed gain
recommendations, and the 6 valve does not. The 6 valve has a maximum gain of about 3.5. This means at
that point, a 1 percent valve position error would cause a 3.5 percent flow error. In contrast, a similar
position error with the 3 valve would result in a 2 percent flow error. The change in gain within the
specified flow range is about 2-to-1 for both valves. The gain of the 3 valve is clearly closer to 1 than the 6
valve. Had a 4 valve been analyzed, it would have been found to be better than the 6 valve, but not as
good as the 3 valve. Note that on the gain graph, 1.0 on the q/qmaz axis will always be the maximum
required flow.

NOTE: The program cannot actually show the results for two valves at one time. The graphs shown above
were produced by combining the results from the two calculations into a single graph. When using the
sizing program, it is possible to quickly step through the graphs for each of several valves to easily
compare them.